Folding chair

Abstract

To provide a folding chair that excels in maintainability.SOLUTION: A folding chair includes: a back plate 21; a seat surface plate 23 that is continuously provided to the back plate; and a pair of side face plates 31 that are installed respectively to both end parts in the width direction of the back plate 21. The folding chair is capable of changing shapes into a use state and a folding state. The seat surface plate 23 is installed continuously to the back plate 21 through a connection plate 22 which is formed integrally with the back plate 21 by extending in a direction intersecting with the back plate 21. The side face plate 31 is rotatably installed to the back plate 21, while the seat surface plate 23 is continuously installed rotatably to the connection plate 22. In the use state, the pair of side face plates 31 are situated in a manner that intersects with the back plate 21, and on top of the pair of side face plates 31, there is placed the seat surface plate 23. In the folding state, the pair of side face plates 31 are arranged oppositely to the back plate 21 in the lower part of the connection plate 22, and the seat surface plate 23 is arranged oppositely to the back plate 21.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a folding chair. [Background technology]

[0002] Folding chairs are known for use by the elderly and young children when putting on or taking off shoes at building entrances. Because building entrances have limited space, folding chairs are useful because they can save space.

[0003] Patent Document 1 describes an invention relating to a foldable entrance bench that can be easily used in appropriate locations such as building entrances, bathrooms, and rooms when support is needed due to physical decline or other reasons. This entrance bench includes a pair of left and right side panels, a seat panel pivotally supported on the side panels so that it can be raised and lowered from a horizontal position to a vertical position, and a pair of leg panels that hold the seat panel in a horizontal position. The seat panel and leg panels are connected by a link mechanism. When the seat panel is raised to a vertical position, the pair of leg panels close inward via the link mechanism. This results in a folded state in which the seat panel is positioned vertically on top of the closed pair of leg panels. When the seat panel is lowered to a horizontal position, the pair of leg panels open outward via the link mechanism to support the seat panel. This results in a usable state in which the seat panel is placed horizontally on top of the open pair of leg panels. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-102582 Summary of the Invention [Problem to be solved by the invention]

[0005] The entrance bench described in Patent Document 1 has a seat panel positioned vertically above a pair of closed leg panels when folded. The link mechanism connecting the seat panel and leg panels is exposed to the outside of the seat panel. Therefore, when folded, dust and debris can easily get in between the pair of leg panels and side panels, and can easily adhere to the link mechanism. This requires the removal or wiping of dust and debris that has gotten inside and that has adhered to the link mechanism, resulting in a maintenance issue. [Means for solving the problem]

[0006] To solve the above problems, the present invention provides a folding chair that can change its shape between a use state and a folded state, and that includes a back panel, a seat panel connected to the back panel, and a pair of side panels attached to both widthwise ends of the back panel. The seat panel is connected to the back panel via a connecting plate that extends in a direction intersecting the back panel and is integrally formed with the back panel, the side panels are rotatably attached to the back panel, and the seat panel is rotatably connected to the connecting plate. In the use state, the pair of side panels are positioned intersecting the back panel, and the seat panel rests on top of the pair of side panels. In the folded state, the pair of side panels are positioned below the connecting plate facing the back panel, and the seat panel is positioned facing the back panel.

[0007] Here, the back panel is the plate material that is located behind the user when the folding chair is in use. The seat panel is the plate material that forms the seat surface. The side panels are the plate materials that are located on both sides of the user. Furthermore, the widthwise ends of the back panel include not only the widthwise end edges of the back panel but also positions near the widthwise end edges.

[0008] According to the above configuration, in the folded state, the pair of side panels are stored below the connecting plate between the opposing seat panel and back panel. Therefore, the connecting plate covers the upper area between the opposing pair of side panels and back panel in the folded state, and the upper area between the opposing seat panel and back panel. This prevents dust and debris from entering the internal space surrounded by the seat panel and back panel. Furthermore, by wiping and cleaning the exterior surfaces surrounded by the back panel, connecting plate, and seat panel, the folding chair can be kept clean in the folded state. This provides a folding chair with excellent maintainability.

[0009] In the above configuration, it is preferable that the back panel, the connecting plate, the seat panel, and the side panels are formed from hollow plate material made of thermoplastic resin with multiple cells arranged side by side inside, the seat panel is formed integrally with the connecting plate, and a seat hinge portion formed by thermally melting the hollow plate material is formed between the seat panel and the connecting plate.

[0010] According to the above configuration, each plate member constituting the folding chair is formed from a hollow plate member made of a thermoplastic resin. Therefore, it is lightweight yet highly strong. Its shape can easily be changed between its in-use state and its folded state, and it also has excellent durability. Furthermore, the seat plate, which is rotatably connected to the connecting plate, is integrally formed with the connecting plate via a seat hinge portion formed by thermally fusing the hollow plate member. Because the connecting plate and the seat plate are formed from a single hollow plate member, the structure is simplified. Furthermore, the seat hinge portion functions as a pivot axis for the seat plate relative to the connecting plate. Because the seat hinge portion as a pivot axis is formed by thermally fusing the hollow plate member, the density of the thermoplastic resin at the seat hinge portion is higher than in other parts. Therefore, the strength of the seat plate can be maintained when it rotates.

[0011] In the above configuration, it is preferable that the device further includes a front panel that is arranged opposite the back panel when in use, the front panel being formed integrally with the side panel, and a front hinge portion formed by thermally fusing a hollow plate material is formed between the front panel and the side panel.

[0012] According to the above configuration, when in use, the front panel supports the seat panel from the front side of the seat panel. This improves the strength of the folding chair when in use. Also, because the front panel is formed integrally with the side panels, the structure is simplified. Furthermore, the density of the thermoplastic resin in the front hinge portion is higher than in other parts, so the strength of the front panel can be maintained when it rotates.

[0013] In the above configuration, it is preferable that the side panel has a side hinge portion formed by thermally fusing a hollow plate material so as to extend in the vertical direction. According to the above configuration, the side panels can be folded at the side hinge portions to be in the folded state, so that the pair of side panels do not overlap each other when in the folded state. [Effects of the Invention]

[0014] According to the present invention, a folding chair with excellent maintainability can be obtained. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view of a folding chair in use. [Figure 2] FIG. 2 is a perspective view of the folding chair in a folded state. [Figure 3] FIG. 3 is a cross-sectional perspective view taken along line 3-3 of FIG. [Figure 4] FIG. 4 is a cross-sectional perspective view taken along line 4-4 of FIG. [Figure 5] FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 2. [Figure 6] FIG. 10 is a diagram illustrating a seat hinge portion. [Figure 7] FIG. 4 is a cross-sectional view of an end portion of the seat panel. [Figure 8] (a) is a partial perspective view of the sound absorbing structure, (b) is a β-β line cross section of (a), and (c) is a γ-γ line cross section of (a). [Figure 9] 1(a) to 1(c) are diagrams illustrating a method for manufacturing a hollow plate material. [Figure 10]10(a) to 10(c) are diagrams illustrating an example of how to use a folding chair. [Figure 11] FIG. 10 is a perspective view of a modified folding chair in use. [Figure 12] FIG. 12 is a cross-sectional perspective view taken along line 12-12 of FIG. [Figure 13] FIG. 10 is a cross-sectional perspective view of a modified folding chair in a folded state. [Figure 14] 10A and 10B are diagrams illustrating a seat hinge portion of a modified example. [Figure 15] FIG. 10 is a horizontal cross-sectional view of a modified folding chair. [Figure 16] FIG. 10 is a vertical cross-sectional view of a folding chair according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0016] An embodiment of a folding chair of the present invention will be described below. The folding chair 10 of this embodiment is attached to a wall surface inside a room when used. The folding chair 10 is formed so that it can change shape between a use state shown in FIG. 1 and a folded state shown in FIG. 2. Hereinafter, the folding chair 10 will be simply referred to as "chair 10." When attached to a wall surface, the up-down direction of the chair 10 is defined, the wall side is defined as the rear side, and the opposite side is defined as the front-to-rear direction, and the direction perpendicular to the up-down direction and the front-to-rear direction is defined as the width direction.

[0017] As shown in Figures 1 and 3, chair 10 comprises a main body 20 and a pair of side panels 31. Main body 20 is formed by integrally connecting back panel 21, connecting panel 22, and seat panel 23. Main body 20 and the pair of side panels 31 are formed from a hollow plate material 1 made of thermoplastic resin with a plurality of cells S arranged side by side inside. The hollow plate material 1 will be described later.

[0018] As shown in Figures 1 and 2, the back panel 21 is formed in a rectangular shape. The chair 10 is fixed to the wall surface in a room with the outer surface of the back panel 21 abutting against the wall surface. Fixing members 41 extending in the vertical direction are attached to both widthwise ends of the back panel 21. The chair 10 is fixed to the wall surface by attaching the fixing members 41 to the wall surface in the room.

[0019] 4 and 5, fixing member 41 is a long metal member. Fixing member 41 includes a planar fixing portion 42 and a U-shaped cross-section receiving portion 43 connected to fixing portion 42. Fixing member 41 is attached with an end of rear panel 21 inserted into receiving portion 43. Rear panel 21 is fixed to the wall surface inside the room by inserting a fixing jig (not shown) into a hole (not shown) formed in fixing portion 42.

[0020] As shown in FIG. 3, the connecting plate 22 is formed in a rectangular shape. The connecting plate 22 extends in the front-rear direction so as to be perpendicular to the back plate 21. A thermally ruled line 24 extending in the width direction is formed between the connecting plate 22 and the back plate 21. The thermally ruled line 24 extends the entire width direction. The thermally ruled line 24 is formed by thermally compressing a portion of the main body 20 into a linearly extending recessed line and then thermally fusing it. Specifically, the thermally fusing upper end of the back plate 21 and the rear end of the connecting plate 22 are joined by cooling and solidifying them.

[0021] 3, the seat plate 23 is formed in a rectangular shape. A seat hinge portion 25 extending in the width direction is formed between the connecting plate 22 and the seat plate 23. 6, seat hinge portion 25 is formed as a recessed strip with a triangular cross section that is formed by reducing the thickness of main body 20. Seat plate 23 is rotatable relative to connecting plate 22, with the thinnest part of seat hinge portion 25 acting as rotation axis 25a.

[0022] As shown in Fig. 7, the front end and both widthwise ends of the seat panel 23 are sealed with strip-shaped plate material 23a. At the front end and both widthwise ends of the seat panel 23, the plate material 23a prevents the cells S formed inside the hollow plate material 1 from being exposed to the outside. The plate material 23a is formed by end surface treatment in which the ends of the hollow plate material 1 are compressed and welded in a press molding process described later. Although not shown in the figure, both widthwise ends of the connecting plate 22 and both widthwise ends and the bottom end of the back panel 21 are also sealed with similar plate material. In addition, the front and rear ends and top and bottom ends of the side panels 31 described later are also sealed with similar plate material.

[0023] As shown in Figures 1 and 3, a reinforcing member 44 extending in the width direction is attached to the front end of the seat panel 23. The reinforcing member 44 is a long metal member. The reinforcing member 44 has a U-shaped cross section, and is attached with the front end of the seat panel 23 inserted inside. In addition, male fasteners (not shown) in the form of strip-shaped hook-and-loop fasteners extending in the front-to-rear direction are attached to both widthwise ends of the underside of the seat panel 23. The width of the male fasteners is approximately equal to the thickness of the side panel 31.

[0024] As shown in Figures 1 and 3, the side panels 31 are rectangular plates. The pair of side panels 31 are fixed to both widthwise ends of the rear panel 21. The outer surfaces of the pair of side panels 31 are substantially flush with both widthwise end faces of the rear panel 21. The side panels 31 are fixed to the rear panel 21 by metal hinge members 45. The hinge members 45 are attached to three locations on the inner surface of the rear panel 21: the upper and lower ends and an intermediate portion between them. The side panels 31 are configured to be rotatable relative to the rear panel 21, with the hinge members 45 serving as rotation axes.

[0025] As shown in Figures 3 and 4, a side hinge portion 32 extending in the up-down direction is formed in approximately the middle of the side panel 31 in the front-to-rear direction. The side hinge portion 32 is formed as a recess with a triangular cross section, where the thickness of the side panel 31 is reduced. The shape of the side hinge portion 32 is the same as the shape of the seat hinge portion 25. The side panel 31 is configured so that a front half portion 31a and a rear half portion 31b thereof can rotate around a rotation axis 32a, which is the thinnest part of the side hinge portion 32. A female fastener in the form of a strip-shaped hook-and-loop fastener is attached to the upper end surface of the side panel 31 (not shown).

[0026] 1 and 2, the length L1 of the lower surface of the seat panel 23 in the front-to-rear direction when in use is approximately equal to the length L2 of the inner surface of the back panel 21 in the up-down direction. The length L3 of the lower surface of the connecting plate 22 in the front-to-rear direction is slightly longer than twice the thickness of the side panel 31. Specifically, the length L3 of the lower surface of the connecting plate 22 in the front-to-rear direction is equal to the distance between the inner surfaces of the back panel 21 and the seat panel 23 in the folded state, and is slightly longer than the total thickness of the side panel 31 in the folded state, as shown in FIG.

[0027] Furthermore, the length L4 of the side panel 31 in the front-to-rear direction when in use is slightly shorter than the sum of the length L1 of the underside of the seat panel 23 in the front-to-rear direction when in use and the length L3 of the underside of the connecting plate 22 in the front-to-rear direction. The length L5 of the side panel 31 in the up-to-down direction is approximately equal to the length L2 of the inner surface of the back panel 21 in the up-to-down direction.

[0028] Next, the structure of the hollow plate material 1 that forms the main body 20 and the side plate 31 will be described. As shown in Figure 8(a), the hollow plate material 1 is composed of a core layer 2 made of thermoplastic resin with multiple cells S arranged side by side inside, and skin layers 3 and 4 made of thermoplastic resin joined to both main surfaces of the core layer 2 so as to cover the entire core layer 2.

[0029] The core layer 2 is formed by folding a single thermoplastic resin sheet material 100 molded into a predetermined shape. The core layer 2 is composed of an upper wall portion 2a, a lower wall portion 2b, and a side wall portion 2c that is erected between the upper wall portion 2a and the lower wall portion 2b and divides the cells S into a hexagonal columnar shape. As will be described below, the upper wall portion 2a and the lower wall portion 2b of the core layer 2 have a mixed structure of a one-layer structure and a two-layer structure, but in FIG. 8(a), the upper wall portion 2a and the lower wall portion 2b of the core layer 2 are shown as having a single-layer structure.

[0030] As shown in Figures 8(b) and (c), the cells S partitioned and formed inside the core layer 2 include a first cell S1 and a second cell S2 with different structures. As shown in Figure 8(b), in the first cell S1, a two-layer upper wall portion 2a is provided on the upper part of the side wall portion 2c. The layers of this two-layer upper wall portion 2a are bonded to each other. In addition, an opening (not shown) is formed in the two-layer upper wall portion 2a due to thermal shrinkage of the thermoplastic resin during molding of the core layer 2. In the first cell S1, a single-layer lower wall portion 2b is provided below the side wall portion 2c.

[0031] On the other hand, as shown in Figure 8(c), in the second cell S2, a single-layer upper wall 2a is provided on the upper part of the side wall 2c. In addition, in the second cell S2, a two-layer lower wall 2b is provided on the lower part of the side wall 2c. The layers of this two-layer lower wall 2b are bonded to each other. An opening (not shown) is formed in the two-layer lower wall 2b due to thermal contraction of the thermoplastic resin during molding of the core layer 2.

[0032] 8(b) and 8(c), adjacent first cells S1 and adjacent second cells S2 are partitioned by sidewalls 2c having a two-layer structure. The two-layer sidewalls 2c have portions that are not heat-welded to each other in the center of the thickness direction of the core layer 2. Therefore, the internal space of each cell S of the core layer 2 is in communication with the internal spaces of the other cells S through the two-layer sidewalls 2c.

[0033] As shown in Figure 8(a), the first cells S1 are arranged in rows along the X direction. Similarly, the second cells S2 are arranged in rows along the X direction. The rows of the first cells S1 and the rows of the second cells S2 are alternately arranged in the Y direction, which is perpendicular to the X direction. The first cells S1 and the second cells S2 form a honeycomb structure as a whole in the core layer 2.

[0034] The thermoplastic resin constituting the core layer 2 and the skin layers 3 and 4 may be any conventionally known thermoplastic resin, such as polypropylene resin, polyamide resin, polyethylene resin, acrylonitrile-butadiene-styrene copolymer resin, acrylic resin, polybutylene terephthalate resin, etc. In this embodiment, the core layer 2 and the skin layers 3 and 4 are made of polypropylene resin. The thermoplastic resin constituting the core layer 2 and the thermoplastic resin constituting the skin layers 3 and 4 are preferably made of the same material. In this embodiment, the skin layers 3 and 4 have the same thickness.

[0035] Next, a method for manufacturing the hollow plate material 1 will be described. As shown in FIG. 9, the hollow plate material 1 is manufactured by forming a core layer 2 from one sheet material 100 and bonding skin layers 3 and 4 to the core layer 2.

[0036] As shown in FIG. 9(a), the sheet material 100 is formed by molding a single thermoplastic resin sheet into a predetermined shape. The sheet material 100 has band-shaped flat regions 110 and bulging regions 120 alternately arranged in the longitudinal direction (X direction) of the sheet material 100. In the bulging region 120, a first bulging portion 121 having a downward groove-like cross section and consisting of an upper surface and a pair of side surfaces is formed over the entire extending direction (Y direction) of the bulging region 120. Note that the angle formed between the upper surface and the side surface of the first bulging portion 121 is preferably 90 degrees, so that the cross section of the first bulging portion 121 has a downward U-shape. The width of the first bulging portion 121 (the length in the short direction of the upper surface) is set to be equal to the width of the flat region 110 and to be twice the bulging height of the first bulging portion 121 (the length in the short direction of the side surfaces).

[0037] In addition, in the bulging region 120, a plurality of second bulging portions 122, each of which has a cross-sectional shape that is a trapezoid obtained by bisecting a regular hexagon along its longest diagonal, are formed so as to be perpendicular to the first bulging portions 121. The bulging height of the second bulging portions 122 is set to be equal to the bulging height of the first bulging portions 121. The interval between adjacent second bulging portions 122 is equal to the width of the upper surface of the second bulging portions 122.

[0038] The first bulging portion 121 and the second bulging portion 122 are formed by partially bulging the sheet upwards by utilizing the plasticity of the sheet. The sheet material 100 can be formed from a single sheet by a well-known forming method such as vacuum forming or compression forming.

[0039] As shown in FIGS. 9(a) and 9(b), the sheet material 100 configured as described above is folded along the boundary lines P and Q to form the core layer 2. Specifically, the sheet material 100 is valley-folded at the boundary line P between the flat region 110 and the bulging region 120, and mountain-folded at the boundary line Q between the top surface and side surface of the first bulging portion 121, thereby compressing it in the X direction. Then, as shown in FIGS. 9(b) and 9(c), the top surface and side surface of the first bulging portion 121 are folded over, and the end surface of the second bulging portion 122 is folded over on the flat region 110, thereby forming one rectangular columnar partition 130 extending in the Y direction for each bulging region 120. These partitions 130 are continuously formed in the X direction, thereby forming the hollow plate-like core layer 2.

[0040] When the sheet material 100 is compressed as described above, the upper wall portion 2a of the core layer 2 is formed by the upper surface and side surface of the first bulge portion 121, and the lower wall portion 2b of the core layer 2 is formed by the end surface of the second bulge portion 122 and the flat region 110. As shown in Fig. 9(c), the portion of the upper wall portion 2a where the upper surface and side surface of the first bulge portion 121 are folded over to form a two-layer structure, and the portion of the lower wall portion 2b where the end surface of the second bulge portion 122 and the flat region 110 are folded over to form a two-layer structure, respectively, become overlapping portions 131.

[0041] Furthermore, a hexagonal columnar region formed by folding the second bulging portion 122 becomes the second cell S2, and a hexagonal columnar region formed between a pair of adjacent partitions 130 becomes the first cell S1. In this embodiment, the upper and side surfaces of the second bulging portion 122 form the side wall 2c of the second cell S2, and the side surfaces of the second bulging portion 122 and the flat portions located between the second bulging portions 122 in the bulging region 120 form the side wall 2c of the first cell S1. The contact areas between the upper surfaces of the second bulging portions 122 and the contact areas between the flat portions in the bulging region 120 form the side wall 2c having a two-layer structure. Note that, when performing this folding process, it is preferable to heat-treat the sheet material 100 to soften it.

[0042] Next, the skin layer 3 is superimposed on the upper surface of the core layer 2, and the skin layer 4 is superimposed on the lower surface of the core layer 2. The skin layers 3 and 4 are preferably softened by heat treatment. By heat treating the skin layers 3 and 4, the thermoplastic resin adhesive layers coated on the skin layers 3 and 4 are partially thermally melted. Therefore, the skin layers 3 and 4 superimposed on the core layer 2 are positioned in a state where they are temporarily bonded to the core layer 2. The adhesive layers solidify as the temperatures of the core layer 2 and the skin layers 3 and 4 decrease, and the skin layers 3 and 4 are bonded to the core layer 2 to form the hollow plate material 1.

[0043] Next, a method for manufacturing a chair 10 using the hollow board material 1 will be described. The chair 10 is manufactured by cutting a hollow plate material 1 to a predetermined size and processing it. The method for manufacturing the chair 10 includes a heating step, a press molding step, and a post-processing step. The heating step is a step of heating the hollow plate material 1. The press molding step is a step of molding the hollow plate material 1 in a mold to obtain an intermediate body. The post-processing step is a step of processing the intermediate body to obtain the chair 10.

[0044] The hollow board material 1 used for the body 20 of the chair 10 is cut into a rectangular shape slightly larger than the body 20, and the hollow board material 1 used for the side panel 31 is cut into a rectangular shape slightly larger than the side panel 31.

[0045] In the heating process, the cut hollow plate material 1 is placed in a heating furnace set to a predetermined temperature and held there for a predetermined time. The temperature inside the heating furnace is set to a temperature at which the thermoplastic resin that makes up the hollow plate material 1 melts.

[0046] In the press molding process, the hollow plate material 1 is clamped in a mold having the same shape as the main body 20 but a slightly larger internal space than the main body 20, and a mold having the same shape as the side panel 31 but a slightly larger internal space than the side panel 31.

[0047] The following describes the formation of the main body 20. In the mold for forming the main body 20, a rectangular plate-shaped internal space having two ridges extending in the width direction is formed by clamping the mold. One of the ridges is a portion for forming the seat hinge portion 25, and the other is a portion for forming the boundary portion between the back panel 21 and the connecting plate 22. The two ridges are formed in a triangular shape in cross section. The height of the internal space in the portion other than the ridges is slightly smaller than the thickness of the hollow plate material 1.

[0048] The hollow plate material 1 heated in the heating process is placed in a mold and clamped to form an intermediate body. The pressure and pressing time during pressing can be set appropriately. The hollow plate material 1 is molded into the shape of the cavity to obtain an intermediate body. The height of the cavity in parts other than the ridges of the mold is slightly lower than the thickness of the hollow plate material 1. Therefore, in parts of the intermediate body other than those corresponding to the ridges of the mold, the hollow plate material 1 is hardly compressed in the thickness direction and maintains its hollow structure. In addition, the thermoplastic resin that makes up the hollow plate material 1 hardly melts. Therefore, the strength of the honeycomb structure is maintained in these parts.

[0049] Meanwhile, recessed strips with triangular cross sections extending in the width direction are formed in the two protruding strips of the mold. One of the recessed strips forms the boundary between the back panel 21 and the connecting plate 22, i.e., the thermal ruled line 24. The other recessed strip forms the boundary between the connecting plate 22 and the seat panel 23, i.e., the seat hinge portion 25. The heated hollow plate material 1 is thermally melted in the recessed strips, and the hollow plate material 1 is compressed in the thickness direction by the protruding strips of the mold.

[0050] The intermediate body is removed from the mold while the hollow plate material 1 is still thermally fused where the grooves are formed. First, the connecting plate 22 is bent at a right angle to the back plate 21 at the grooves that form the boundary between the back plate 21 and the connecting plate 22. This brings one slanted surface of the groove into contact with the other slanted surface, and they are then bonded together by cooling. The back plate 21 and the connecting plate 22 are bonded at a right angle to form the thermal score 24.

[0051] As shown in FIG. 6 , the grooves that form the boundary between the seat panel 23 and the connecting plate 22 are left as they are without bending, forming the seat hinge portion 25. In the seat hinge portion 25, the thermoplastic resin that forms the hollow plate 1 is thermally melted and compressed in the thickness direction. This increases the density of the thermoplastic resin compared to the density in the hollow plate 1. The portion that is most compressed in the thickness direction becomes the pivot axis 25a of the seat hinge portion 25. In the pivot axis 25a, the thermoplastic resin that forms the upper wall portion 2a, the lower wall portion 2b, and the side wall portion 2c of the core layer 2 is thermally melted, and the thermoplastic resin that forms the skin layers 3 and 4 is also thermally melted and integrated, forming a gap-free state. In the state where the thermoplastic resin is integrated, the pivot axis 25a has the bending rigidity to rotatably connect the seat panel 23 to the connecting plate 22 and maintains its strength as the pivot axis 25a.

[0052] In addition, a heating rod (not shown) is pressed against each side of the entire periphery of the end of the intermediate body. The heating rod heats and melts the thermoplastic resin that makes up the intermediate body, and it is crushed. As a result, a thin-walled portion is formed around the entire periphery of the end of the intermediate body, where the core layer 2 and the skin layers 3 and 4 that make up the hollow plate material 1 are integrated. Next, the thin-walled portion is raised toward the core layer 2 and welded. As a result, the entire periphery of the end of the intermediate body is sealed with the thin-walled portion, which is a strip-shaped plate material. The thin-walled portion becomes the plate material 23a of the seat plate 23 shown in Figure 7.

[0053] The side panel 31 is also press-molded in the same manner. By press molding, a side hinge portion 32 having a rotation axis 32a is formed in the side panel 31. The state of the thermoplastic resin in the side hinge portion 32 and the rotation axis 32a is the same as that of the seat hinge portion 25 and the rotation axis 25a. The bending rigidity and strength of the rotation axis 32a are maintained when the front half portion 31a and rear half portion 31b of the side panel 31 rotate. In addition, by thermally melting the entire periphery of the end of the side panel 31 with a heating blade, the end of the side panel 31 is sealed with a strip-shaped plate material.

[0054] Through the above steps, the main body 20 and the side panel 31 are formed. Next, a description will be given of the post-processing step in which the main body 20 and side panels 31 are processed to obtain the chair 10. In the post-processing step, fixing members 41 are attached to both widthwise ends of the back panel 21 of the main body 20, and a reinforcing member 44 is attached to the front end of the seat panel 23. In addition, a male fastener as a hook-and-loop fastener is attached to the underside of the seat panel 23.

[0055] Next, female fasteners as hook-and-loop fasteners are attached to the upper end surfaces of the side panels 31. Then, hinge members 45 are attached to three locations on the rear end of the side panels 31, and the side panels 31 and the back panel 21 are fixed together by the hinge members 45. Through the above steps, chair 10 is obtained.

[0056] Next, how to use the chair 10 and its function will be described. First, the case where the folded state shown in FIG. 2 is changed to the usage state shown in FIG. 1 will be described. Chair 10 is fixed to the wall surface of the room by fixing members 41. In the folded state, seat panel 23 is disposed on the front side facing the wall surface of the room. In this state, the lower end of seat panel 23 is lifted forward. Because seat hinge portion 25 is formed between seat panel 23 and connecting plate 22, seat panel 23 rotates around rotation axis 25a of seat hinge portion 25. Seat panel 23 is lifted slightly above the position where it is horizontal with connecting plate 22.

[0057] Next, each of the pair of side panels 31 in the folded state is pulled forward. The side panels 31 are attached to the back panel 21 by hinge members 45, and a side hinge portion 32 is formed between the front half 31a and rear half 31b of the side panel 31. Therefore, the side panels 31 rotate about the hinge members 45 and the rotation shafts 32a of the side hinge portions 32. The side panels 31 are pulled out to a position where they are perpendicular to the back panel 21.

[0058] The seat panel 23 is placed on top of the pulled-out side panel 31. Because the vertical length L5 of the side panel 31 is approximately equal to the vertical length L2 of the inner surface of the back panel 21, the seat panel 23 placed on top of the side panel 31 extends horizontally together with the connecting plate 22. At this time, the female fastener on the upper end surface of the side panel 31 and the male fastener on the underside of the seat panel 23 are joined. This positions the side panel 31 and stabilizes its position.

[0059] Next, a description will be given of the case where the portable telephone is changed from the use state shown in FIG. 1 to the folded state shown in FIG. First, the seat panel 23 is lifted slightly above a position where it is horizontal with the connecting plate 22. This releases the connection between the female fastener on the upper end surface of the side panel 31 and the male fastener on the underside of the seat panel 23. In this state, the side panel 31 is folded backward. The side panel 31 rotates around the hinge member 45 and the rotation axis 32a of the side hinge portion 32, and the front half portion 31a and the rear half portion 31b are positioned opposite to and parallel to the back panel 21. Then, the seat panel 23, which has been lifted upward, is lowered. The seat panel 23 rotates around the rotation axis 25a of the seat hinge portion 25, and is positioned opposite to and parallel to the back panel 21.

[0060] At the seat hinge portion 25 and the side hinge portion 32, the thermoplastic resin that makes up the hollow plate material 1 is thermally melted and compressed in the thickness direction, so that the density of the thermoplastic resin is higher than that of the hollow plate material 1. Furthermore, the pivot shafts 25a and 32a are most compressed in the thickness direction, so that the thermoplastic resin is in a unified state. This allows for smooth rotation when rotating the seat panel 23 and the side panel 31, and provides sufficient strength to withstand such rotation.

[0061] The length L3 in the front-to-rear direction of the lower surface of the connecting plate 22 is slightly longer than the total thickness of the side panels 31 in the folded state (twice the thickness of the side panels 31 in this embodiment). Therefore, in the folded state, the folded side panels 31 are stored in the internal space between the back panel 21 and the seat panel 23, and their upper parts are covered by the connecting plate 22. Furthermore, the length L1 in the front-to-rear direction of the lower surface of the seat panel 23 is approximately equal to the length L2 in the up-down direction of the inner surface of the back panel 21. Therefore, in the folded state, the front of the folded side panels 31 is covered by the seat panel 23.

[0062] As shown in FIG. 10, a case will be described in which three such chairs 10 are fixed adjacent to each other to the wall of a room. FIG. 10(a) is a diagram showing the case where all three chairs are folded. In this case, the space inside the room can be used more widely. FIG. 10(b) is a diagram showing the case where the two chairs on both sides are in an in-use state. In this case, the chairs 10 in an in-use state can be used as seats, and the spaces below the chairs 10 can be used as storage space for luggage. For example, a desk can be placed in front of the chairs 10 in a folded state. Furthermore, FIG. 10(c) is a diagram showing the case where all the chairs are in an in-use state. In this case, all the chairs 10 can be used as seats, or they can be used as beds. Furthermore, the spaces below all the chairs 10 can be used as storage space for luggage.

[0063] According to the chair 10 of this embodiment, the following effects can be obtained. (1) The main body 20 of the chair 10 is formed by integrally connecting a back panel 21, a connecting plate 22, and a seat panel 23. In the folded state, the pair of side panels 31 are disposed below the connecting plate 22 facing the back panel 21, and the seat panel 23 is disposed facing the back panel 21.

[0064] Therefore, in the folded state, the pair of side panels 31 are stored below the connecting plate 22, between the opposing seat panel 23 and back panel 21. The space between the opposing seat panel 23 and back panel 21 forms a storage space for the pair of side panels 31, and the upper part of this space is covered by the connecting plate 22. This prevents dust and debris from entering the storage space for the side panels 31. Furthermore, in the folded state, the chair 10 can be kept clean by simply wiping the exterior surface of the main body 20. This makes the chair 10 easy to maintain.

[0065] Furthermore, by folding it up, it is possible to save space, and the space inside the room can be used effectively. (2) The main body 20 and the side panels 31 are formed from a hollow plate material 1 made of a thermoplastic resin, in which a plurality of cells S are arranged side by side.

[0066] Therefore, it is lightweight yet highly strong. (3) The main body 20, which is formed by integrally connecting the back panel 21, the connecting panel 22, and the seat panel 23, is formed by pressing one hollow plate material 1 in a mold.

[0067] Therefore, the manufacturing process of the main body 20 can be simplified. (4) The seat hinge portion 25 and the side hinge portion 32 are formed by thermally melting the hollow plate material 1. The density of the thermoplastic resin is high at the rotation shafts 25a and 32a.

[0068] Therefore, the chair 10 has sufficient bending elasticity and strength to withstand rotational operations, resulting in a chair 10 with excellent durability. (5) The side panel 31 can be folded by the side hinge portion 32 with the front half 31a and rear half 31b overlapping each other.

[0069] Therefore, when the folding device is folded, the pair of side panels 31 can be prevented from overlapping with each other. (6) A metal reinforcing member 44 extending in the width direction is attached to the front end of the seat plate 23.

[0070] Therefore, the strength of the seat plate 23 can be maintained when the occupant sits on it. (7) In use, the side panel 31 and the seat panel 23 are joined together by hook-and-loop fasteners. Therefore, the side panel 31 is positioned and the usage state is stable.

[0071] (8) The length L3 of the lower surface of the connecting plate 22 in the front-rear direction is slightly longer than the total thickness of the side plates 31 in the folded state. Therefore, in the folded state, the folded side panel 31 is stored in the internal space between the back panel 21 and the seat panel 23, and its upper part is covered by the connecting panel 22. Also, it is possible to make the gap between the folded side panel 31 and the back panel 21, and between the folded side panel 31 and the seat panel 23 almost zero. This makes it possible to reduce the thickness of the chair 10 in the folded state, contributing to space saving.

[0072] (9) The length L1 of the lower surface of the seat panel 23 in the front-rear direction is approximately equal to the length L2 of the inner surface of the back panel 21 in the up-down direction. Therefore, in the folded state, the front of the folded side panel 31 is covered by the seat panel 23. This prevents the side panel 31 from being exposed to the outside. This makes it difficult for dust and dirt to adhere to the side panel 31, improving maintainability.

[0073] The above-described embodiment can be modified as follows: Each embodiment and the following modifications can be combined with each other within the scope of technical compatibility. In the chair 10 of the above embodiment, when in use, the side panels 31 extend in the front-rear direction at both widthwise ends. However, the shape of the chair 10 is not limited to this.

[0074] 11 and 12, a front panel 51 may be provided that is formed integrally with the side panel 31. The front panel 51 is rotatable relative to the side panel 31 via a front hinge portion 52. The shape of the front hinge portion 52 is the same as the shape of the seat hinge portion 25 and the side panel hinge portion 32. In other words, the front hinge portion 52 allows the front panel 51 to rotate relative to the side panel 31, using the portion of the hollow plate material 1 where the thickness is thinnest as a rotation axis 52a.

[0075] As shown in Fig. 12, when front panel 51 is rotated and positioned so as to extend along side panel 31, the surface on which front hinge portion 52 is formed is opposite the surface on which side hinge portion 32 is formed. Therefore, as shown in Fig. 13, in the folded state, front panel 51 can be folded so as to overlap in front of side panel 31. As a result, rear half portion 31b and front half portion 31a of side panel 31 and front panel 51 are folded so as to form an N shape when viewed from above.

[0076] The seat panel 23 is formed integrally with the connecting plate 22 via the seat hinge portion 25, but may be formed separately from the connecting plate 22. For example, the seat panel 23 may be connected via a hinge member that is a separate member.

[0077] The side panel 31 has a front half 31a and a rear half 31b integrally formed via a side hinge 32, but the front half 31a and the rear half 31b may be formed separately. Alternatively, the front half 31a and the rear half 31b may be connected via a separate hinge member.

[0078] 11 is formed integrally with the side panel 31 via the front hinge portion 52, it may be formed separately from the side panel 31. It may also be connected via a hinge member that is a separate member.

[0079] When the chair 10 is in use, the side panels 31 do not have to extend perpendicular to the back panel 21. For example, the distance between the pair of side panels 31 may be wider or narrower toward the front.

[0080] The hook-and-loop fasteners provided on the side panels 31 and the seat panel 23 can be omitted. Instead of using a hook-and-loop fastener, other fastening means may be used to fasten the side panel 31 to the seat panel 23. For example, magnets or rivets may be used.

[0081] The hook-and-loop fasteners do not have to be formed in a strip shape. They may also be provided at multiple locations in the front-rear direction of the side panel 31 and the seat panel 23. The pair of side panels 31 are fixed to both widthwise ends of the rear panel 21 so that the outer surfaces of the pair of side panels 31 are substantially flush with both end faces of the rear panel 21, but the fixing positions are not limited to this. As long as they are fixed to both widthwise ends of the rear panel 21, they may be positioned closer to the center in the width direction than both widthwise end faces of the rear panel 21.

[0082] The connecting plate 22 may be a curved plate rather than a flat plate. There are no particular limitations on its shape as long as it is formed integrally with the back plate 21 and can cover the side plate 31 from above. The connecting plate 22 does not have to be perpendicular to the back plate 21. It is sufficient that it extends in a direction intersecting the back plate 21 and that the side plate 31 can be stored below it in the folded state.

[0083] The main body 20 and the side panels 31 are formed from hollow plate materials 1, but are not limited to this and may be formed from solid plate materials. Although thermal lines 24 are formed between the connecting plate 22 and the rear plate 21, the thermal lines 24 do not have to be formed. For example, a solid plate material may be formed into a shape bent at a right angle.

[0084] The main body 20 and side panels 31 do not necessarily have to be manufactured by the manufacturing method described in the above embodiment. For example, after cutting the hollow plate 1 into a rectangular shape, a heating rod is used to form thin-walled sections around the entire periphery of the main body 20 and side panels 31, and the ends are sealed. The seat hinge portion 25 and side hinge portion 32 are formed as shown in FIG. 14. If FIG. 14 is explained as showing the seat panel 23 and connecting plate 22, for example, a cutting blade T is pressed against the hollow plate 1 from the skin layer 4 side. At this time, the cutting blade T is pressed to a depth that does not reach the skin layer 3. This cuts the hollow plate 1 partway through its thickness, forming a half cut 26. The seat panel 23 can rotate relative to the connecting plate 22, with the half cut 26 as the rotation axis.

[0085] In the above embodiment, the bearing surface hinge portion 25 is formed by clamping a mold having a triangular cross-sectional ridge formed therein, but the ridge does not have to be triangular in cross-section. A cutting edge T-shaped ridge may also be formed as shown in FIG.

[0086] The side panel 31 is fixed to the back panel 21 by a metal hinge member 45, but this is not limiting. For example, FIG. 15 shows a horizontal cross section of a modified chair 10. The side panel 31 shown in FIG. 15 is bent at a right angle across the heat-sealed line 24, with a portion of the side panel extending along the back panel 21. In this case, the back panel 21 and the side panel 31 may not be fixed by the metal hinge member 45, but may be fixed by attaching a hook-and-loop fastener 46 across the portion of the side panel 31 that is along the back panel 21 and the back panel 21. Not using the metal hinge member 45 makes the chair easier to recycle.

[0087] The folding method of the side panels 31 is not limited to that of the above embodiment. For example, as shown in Fig. 15, two side hinge portions 321, 322 may be formed on each side panel 31. In this case, one side panel 31 may be folded at the side hinge portion 321, and the other side panel 31 may be folded at the side hinge portion 322, so that the pair of side panels 31 can be folded in an overlapping state. Alternatively, one side panel 31 may be folded at the side hinge portion 322, and the other side panel 31 may be folded at the side hinge portion 321.

[0088] As shown in Fig. 16, instead of or in addition to the hook-and-loop fastener, a configuration for positioning the side panel 31 relative to the seat panel 23 may be provided. Fig. 16 shows a state in which support portions 23b that protrude downward and extend in the front-to-rear direction are formed by thermal bending at both widthwise ends of the seat panel 23. In this case, positioning can be achieved by abutting the outer surface of the side panel 31 against the inner surface of the support portions 23b.

[0089] Alternatively, an L-shaped frame extending in the front-rear direction may be attached to the underside of both ends of the seat panel 23. In this case, the side panel 31 can be positioned by abutting it against the inner surface of the L-shaped frame.

[0090] In the manufacturing method of the main body 20 of the chair 10, the grooves that become the seat hinge portion 25 and the grooves that become the thermal score 24 are formed in the mold during the press molding process, but these grooves may be formed in separate processes. For example, the grooves that become the seat hinge portion 25 are formed in the mold, and after removal from the mold, the grooves are formed by pressing with a heating rod. The thermal score 24 is formed by bending the grooves formed by the heating rod and cooling and solidifying them. Alternatively, the seat hinge portion 25 is formed by cooling and solidifying the grooves formed by the heating rod without bending them. The same applies to the side panels 31.

[0091] The core layer 2 is not limited to being formed by folding a single sheet material 100. For example, the side walls of the cells may be formed by bending and arranging a plurality of strip-shaped sheets at predetermined intervals, and sheet layers may be arranged above and below these strip-shaped sheets to form the upper and lower walls of the cells.

[0092] In the above embodiment, the core layer 2 is partitioned into hexagonal prism-shaped cells S, but the shape of the cells S is not particularly limited. For example, the cells S may be polygonal, such as a square prism or an octagonal prism, or cylindrical. The cells S may also be frustoconical. In this case, cells of different shapes may be mixed. Furthermore, the cells do not have to be adjacent to each other, and gaps (spaces) may exist between the cells.

[0093] The core layer 2 is not limited to one in which columnar cells S are partitioned. For example, it may be one in which sheet layers are bonded to both the top and bottom surfaces of a core layer having a predetermined uneven shape. An example of a core layer having such a configuration is that described in JP 2014-205341 A. Alternatively, it may be a plastic cardboard with a harmonica-shaped cross section.

[0094] In the above embodiment, one sheet material 100 is folded and formed to form the core layer 2 as a honeycomb structure in which hexagonal cells S are partitioned inside the core layer 2, but the forming method is not limited to this. For example, as described in Japanese Patent No. 4368399, the core layer 2 as a honeycomb structure may be formed by sequentially folding a three-dimensional structure in which multiple rows of convex portions with trapezoidal cross sections are arranged.

[0095] The thermoplastic resins constituting the core layer 2 and the skin layers 3 and 4 may contain various functional resins. For example, adding a flame-retardant resin to a thermoplastic resin can improve flame retardancy. Various functional resins may be added to all of the core layer 2 and the skin layers 3 and 4, or may be added to at least one of the core layer 2 and the skin layers 3 and 4.

[0096] Although the skin layers 3 and 4 have a single-layer structure, they may have a multi-layer structure. The skin layers 3, 4 of the hollow plate 1 are made of a sheet material made of thermoplastic resin, but at least one of them can also be made of nonwoven fabric. When the skin layers 3, 4 are made of nonwoven fabric, one side can be coated with an adhesive layer made of a thermoplastic resin (e.g., polypropylene resin) and bonded to the core layer 2 via the adhesive layer. The nonwoven fabric that makes up the skin layers 3, 4 can be made of various conventionally known fibers, such as polyamide fiber, aramid fiber, cellulose fiber, polyester fiber, polyethylene fiber, polypropylene fiber, rayon fiber, and glass fiber. When both the skin layers 3, 4 are made of nonwoven fabric, the skin layers 3 and 4 may have the same or different configurations.

[0097] The nonwoven fabric may be attached to at least one of the skin layers 3 and 4 . The skin layers 3 and 4 may be made of a resin film printed thereon, which can improve the design of the chair 10.

[0098] The technical concepts that can be understood from the above-described embodiments and modifications will be described below. (i) A folding chair having a back panel, a seat panel connected to the back panel, a pair of side panels attached to each of the widthwise ends of the back panel, and a front panel connected to the front ends of the side panels, and capable of changing shape between a used state and a folded state, wherein the seat panel is connected to the back panel via a connecting plate that extends in a direction intersecting the back panel and is formed integrally with the back panel, the seat panel is rotatably connected to the connecting plate, the side panels are rotatably attached to the back panel, and the front panel is rotatably connected to the side panels, wherein in the used state, the pair of side panels are positioned so as to intersect with the back panel, and the front panel is positioned opposite the back panel, and the seat panel is placed on top of the pair of side panels and the front panel, and in the folded state, the pair of side panels and the front panel are positioned opposite the back panel below the connecting plate, and the seat panel is positioned opposite the back panel.

[0099] (b) The folding chair described in (a) above, characterized in that the back panel, the connecting panel, the seat panel, the side panels, and the front panel are formed from hollow plate material made of thermoplastic resin with a plurality of cells arranged side by side inside, the seat panel is formed integrally with the connecting plate, the front panel is formed integrally with the side panels, a seat hinge portion formed by heat-melting the hollow plate material is formed between the seat panel and the connecting plate, and a front hinge portion formed by heat-melting the hollow plate material is formed so as to extend in the vertical direction between the front panel and the side panels.

[0100] (c) A folding chair as described in (b) above, characterized in that the side panels are formed with side hinge portions extending in the vertical direction, the side hinge portions being made by thermally fusing hollow board material. (d) A folding chair as described in (c) above, characterized in that the side hinge portion is formed on the surface opposite to the surface on which the front hinge portion is formed on the side panel and the front panel. [Explanation of symbols]

[0101] S...cell 1…Hollow plate material 10...Chair (folding chair) 21...Back plate 22...Connection plate 23… Seat plate 25...Seat hinge 31...Side plate 32...Side hinge 51...Front plate 52...Front hinge

Claims

1. A folding chair having a back panel, a seat panel connected to the back panel, and a pair of side panels attached to both ends of the back panel in the width direction, and capable of changing its shape between an in-use state and a folded state, The seat panel is connected to the back panel via a connecting plate extending in a direction intersecting the back panel, The chair includes a main body in which the back panel, the connecting panel, and the seat panel are integrally formed, and the side panel is formed separately from the main body, the main body and the side panels are formed of hollow plates made of thermoplastic resin with a plurality of cells arranged side by side inside, A reinforcing member extending in the width direction is attached to the front end of the seat plate, the side panel is rotatably attached to the rear panel by a hinge member, A seat hinge portion formed by thermally fusing a hollow plate material is formed between the seat plate and the connecting plate, and the seat plate is rotatably connected to the connecting plate, In a use state, the pair of side panels are positioned so as to intersect with the back panel, and the seat panel is placed on top of the pair of side panels, In the folded state, the pair of side panels are disposed opposite the back panel below the connecting plate, and the seat panel is disposed opposite the back panel; A folding chair characterized in that the length of the lower surface of the connecting plate in the front-to-rear direction is slightly longer than the total thickness of the side panels in the folded state.

2. A folding chair as described in Claim 1, characterized in that it is provided with a structure for positioning the side panels relative to the seat panel when in use.

3. a front plate disposed opposite the rear plate in an in-use state; The front panel is integrally formed with the side panel, 3. The folding chair according to claim 2, wherein a front hinge portion is formed between the front panel and the side panel by thermally fusing a hollow plate material.

4. 3. The folding chair according to claim 1, wherein the side panels are formed with side hinges extending in the vertical direction and made by thermally fusing hollow board material.

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