Foldable durable product, such as a patient aid device or walker, and method of forming same

Abstract

A method of manufacturing a patient aid device, such as a walker (W), includes the steps of molding a polymer or plastic connector ( 60 ) over first and second metal structural members ( 22 , CB) to maintain the structural members in a first geometrical relationship. After the plastic has cured, the method includes the step of rotating the first structural member or front leg ( 22 ) relative to the plastic connector ( 60 ) to form an integral hinge without any seam in the plastic. The resultant walker includes front legs ( 22 ) hinged via the connectors ( 60 ) at opposite ends of the front cross brace (CB). The front leg ( 22 ) and rear leg ( 24 ) of each side frame (SF 1 , SF 2 ) of the walker are interconnected by a lower cross brace ( 40 ) that has plastic preferably molded about the entire periphery of each leg.

1 . A method of manufacturing a product that includes first and second metal structural members joined with plastic and in which one of the first and second structural members can rotate relative to the plastic, the method comprising the steps of:
 providing first and second metal structural members;   molding a polymer member over the first and second structural members to maintain the structural members in a defined geometrical relation; and   rotating the first structural member relative to the polymer member after the polymer has cured to form an integral hinge without any seam in the polymer member.   
   
   
       2 . The method of  claim 1  comprising the further step of entirely inserting at least one of the first and second structural members in a mold press before the molding step. 
   
   
       3 . The method of  claim 1  comprising the further step of deforming a portion of one of the structural members prior to the molding step. 
   
   
       4 . The method of  claim 3  wherein the deforming step is completed in the mold press prior to the molding step and is responsive to one of closing of the mold press or movement of a piston associated with injection molding of the polymer member. 
   
   
       5 . The method of  claim 1  comprising the further step of deforming a portion of the structural member before introducing the structural member into a mold press. 
   
   
       6 . The method of  claim 1  comprising the further step of incorporating a silicone in the polymer for lubricity. 
   
   
       7 . The method of  claim 1  wherein the molding step includes introducing the polymer around an entire peripheral portion of the first structural member whereby a portion of the first structural member is entirely encapsulated by the polymer without a seam. 
   
   
       8 . The method of  claim 1  comprising the step of forming the product into a patient aid device. 
   
   
       9 .- 24 . (canceled) 
   
   
       25 . A durable product comprising:
 first and second metal structural members   a plastic molded over at least portions of the first and second metal structural members so that the structural members are maintained in a desired geometrical relation, the plastic received over the first structural member without any seam in the plastic; and   the first structural member rotating relative to the plastic.   
   
   
       26 . The product of  claim 25  wherein the product is a patient aid product, wherein the first structural member is a leg. 
   
   
       27 . The patient aid product of  claim 25  wherein the product is a walker and the metal structural member includes a front leg of the walker, and the polymer member interconnects the front leg to a front cross brace member. 
   
   
       28 . The walker of  claim 27  further comprising first and second side frames, each side frame including:
 first and second legs having adjacent first ends interconnected by a handle and adjacent second ends interconnected by a lower cross brace, the lower cross brace being secured to each of the first and second legs by encompassing the entire circumferential extend thereof without any seam; and   the front cross brace member interconnecting the first and second side frames through a tube connector.   
   
   
       29 . The walker of  claim 28  further comprising a recess formed in each of the first and second legs to prevent movement of the lower cross brace relative thereto. 
   
   
       30 . The walker of  claim 29  further comprising first and second lock bodies received over respective first legs of the first and second side frames, each lock body including a flange extending outwardly therefrom. 
   
   
       31 . The walker of  claim 30  wherein each lock body extends about the entire circumference of the respective first leg. 
   
   
       32 . The walker of  claim 30  wherein the tube connector includes a recess dimensioned to receive an end of the front cross brace, each recess having a conformation to prevent rotation of the cross brace member relative thereto. 
   
   
       33 . The walker of  claim 30  further comprising first and second tube connectors, each tube connector cooperating with the flange of a respective lock body. 
   
   
       34 . The walker of  claim 33  further comprising a pin and a biasing member interposed between the tube connector and lock body. 
   
   
       35 . The walker of  claim 27  further comprising a plug received in the front cross brace to prevent plastic from entering the interior thereof. 
   
   
       36 . The walker of  claim 35  wherein the plug is secured to the front cross brace to maintain its position with the front cross brace. 
   
   
       37 . A method of manufacturing a walker comprising the steps of:
 providing first and second side frames, each side frame including a front leg;   providing a front cross brace;   molding connectors over opposite ends of the front cross brace; and   subsequently assembling the front cross brace to the side frames by sliding the connectors over respective front legs of the side frames; and   then securing the front cross brace to the front legs.