Note: Descriptions are shown in the official language in which they were submitted.
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BODY SUPPORT ASSEMBLY AND METHODS FOR THE USE AND
ASSEMBLY THEREOF
[0001] This application claims the benefit of U.S. Provisional
Application No.
62/947,911, filed December 13, 2019 and entitled "Body Support Assembly and
Methods for the Use and Assembly Thereof," claims the benefit of U.S.
Provisional Application 62/947,914, filed December 13, 2019 and entitled "Body
Support Assembly and Methods for the Use and Assembly Thereof," and also
claims the benefit of U.S. Application 16/794,946, filed February 19, 2020 and
entitled "Body Support Assembly and Methods for the Use and Assembly
Thereof," the entire disclosure of which is hereby incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present application relates generally to a body support
assembly,
for example a chair, and in particular to a backrest assembly and/or seat
assembly
incorporated into the body support assembly, and various components
incorporated therein, together with methods for the use and assembly thereof.
BACKGROUND
[0003] Chairs, and in particular office chairs, may have a body support
member configured with a suspension material, such as a mesh fabric, that is
stretched across a frame. Such suspension materials conform to the body of the
user, providing micro compliance along with improved air circulation, and the
attendant cooling benefit. Typically, the frame must be rigid in order to
maintain
an appropriate level of tension in the suspension material. Such rigidity may
limit,
however, the flexibility of the body support member, and introduce unforgiving
pressure points around the perimeter of the frame. In addition, suspension
materials installed on a seat of a chair are typically required to sustain
higher
tensions due to the load being applied thereto by a seated user, which may
exacerbate the limited flexibility and rigidity of the supporting structure.
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[0004] While various mechanical systems, such as lumbar supports and tilt
control mechanisms, may be introduced to mitigate the limited flexibility and
provide additional adjustment capabilities, such systems are relatively
expensive
to manufacture, require additional maintenance, are susceptible to wear and
tear
over time, and may not be appropriately exploited by the user due to the
requirement for individual adjustments. In addition, such tilt mechanisms
typically include one or more rigid links, and mechanical connections, which
are
rigid and non-compliant, which result in a more rigid and less forgiving ride,
and
which may lead to a less desirable user experience. Conversely, systems
relying
on the materiality of the seating structure to introduce the appropriate
kinematics
and flexibility may not be suitable to support a suspension material. While
body
support surfaces may be defined by one or more foam cushions, foam materials
may limit air circulation and often do not provide localized support. In
addition,
body support members configured with plastic shells, supported for example by
peripheral frames, typically do not provide a comfortable body-conforming
support surface.
SUMMARY
[0005] The present invention is defined by the following claims, and
nothing in
this section should be considered to be a limitation on those claims.
[0006] In one aspect, one embodiment of a seat assembly includes a lower
support platform having a first peripheral edge, an upper surface and a lower
surface. A support ring is coupled to the first peripheral edge of the lower
support
platform and extends radially outwardly therefrom and defines a second
peripheral
edge. The support ring includes an upper surface. An upper shell is disposed
over
the upper surfaces of the lower support platform and the support ring and
defines a
concave cavity. The upper shell has a third peripheral edge defining a central
opening and an upper surface. A suspension material is secured to the upper
shell
across the central opening and covers the concave cavity.
[0007] In another aspect, one embodiment of a body support member
includes
a carrier frame having a body facing first surface, a second surface opposite
the
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first surface, a peripheral edge surface extending between the first and
second
surfaces, and a peripheral groove formed in and opening outwardly from the
peripheral edge surface. A support frame includes a first surface and a
peripheral
edge. A flexible edge member is connected to the peripheral edge of the
support
frame. The flexible edge member has an inner surface spaced apart from and
facing the peripheral edge surface of the carrier frame. The inner surface and
the
peripheral edge surface define a gap therebetween, with the gap being in
communication with the peripheral groove. A textile material includes a
peripheral edge. The textile material covers the first surface of the carrier
frame
and is disposed in the gap between the inner surface of the flexible edge and
the
peripheral edge surface of the carrier frame. The textile material engages at
least a
portion of the peripheral edge surface of the carrier frame. The peripheral
edge of
the textile material is disposed in the peripheral groove.
[0008] In another aspect, one embodiment of a method of manufacturing a
body support member includes disposing a peripheral edge of a textile material
into a groove formed in a peripheral edge surface of a carrier frame, covering
at
least a portion of the peripheral edge surface and a body-facing first surface
of the
carrier frame with the textile material, and connecting a flexible edge member
to
the carrier frame. The flexible edge member has an inner surface spaced apart
from and facing the peripheral edge surface of the carrier frame, wherein the
inner
surface and the peripheral edge surface define a gap therebetween, wherein the
gap is in communication with the peripheral groove, and wherein the textile
material is disposed in the gap.
[0009] In another aspect, one embodiment of a seat assembly includes a
lower
support platform extending in a longitudinal direction. The lower support
platform includes opposite side edges and a laterally extending first flex
region
extending between the opposite side edges that bifurcates the lower support
platform into a front portion and a rear portion. The first flex region is
bendable
such that the rear portion is downwardly deflectable relative to the front
portion,
even though both the front and rear portions may move upwardly during recline
in
one embodiment. An upper shell includes opposite side members connected to the
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support platform with a pair of connectors. Each of the connectors includes a
second flex region, wherein the second flex regions are bendable such that the
opposite side members are upwardly moveable relative to the lower support
platform as the rear portion is downwardly deflectable.
[0010] In another aspect, a body support member includes a carrier frame
having a central portion and a peripheral ring connected to the central
portion with
a plurality of connectors each having a flex region, with the peripheral ring
defining a central opening. An elastic textile material is coupled to the
peripheral
ring across the central opening. A cushion is disposed between the central
portion
and the textile material. At least one the plurality of connectors is inwardly
deflectable a first amount from a first unloaded configuration to a first
loaded
configuration in response to a load applied to the elastic material, and the
elastic
material is downwardly deflectable a second amount from a second unloaded
configuration to a second loaded configuration in response to the load applied
thereto. The cushion engages and provides auxiliary support to the elastic
material
when the first and second amounts of deflection result in the elastic material
contacting the cushion.
[0011] In another aspect, one embodiment of a body support member
includes
a flexible carrier frame deformable from an unloaded configuration to loaded
configuration, an elastic textile material coupled to the carrier frame, and a
cushion disposed beneath the textile material. The flexible carrier frame,
elastic
material and cushion provide first, second and third amounts of resilient
support to
a user engaging and supported by the textile material.
[0012] In another aspect, one embodiment of a body support member
includes
a carrier frame having opposite side portions defining an opening
therebetween.
An elastic textile material is coupled to the side portions across the
opening, with a
cushion disposed beneath the textile material. At least one of the side
portions,
and preferably both side portions, are inwardly deflectable a first amount
from a
first unloaded configuration to a first loaded configuration in response to a
load
applied to the elastic material. The elastic material is downwardly
deflectable a
second amount from a second unloaded configuration to a second loaded
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configuration in response to the load applied thereto, and the cushion engages
and
provides auxiliary support to the elastic material when the first and second
amounts of deflection result in the elastic material contacting the cushion.
[0013] In another aspect, one embodiment of a body support assembly
includes
a base member and a lower support structure having a longitudinally extending
portion coupled to the base member at a first location, a front link extending
upwardly from the longitudinally extending portion forwardly of the first
location,
and a rear link extending upwardly from the longitudinally extending portion
rearwardly of the first location. A back frame includes a first lower portion
extending rearwardly from the rear link and an upright portion extending
upwardly
from the lower portion. A seat support member is coupled to the front link and
to
the rear link, wherein the seat support member supports a seating surface. A
back
support is pivotally connected to the upright portion at a second location
above the
seating surface and includes a second lower portion connected to the rear link
below the seat support member.
[0014] In another aspect, one embodiment of a backrest assembly includes
a
base and a rigid back frame having a first upright portion and a first lower
portion
extending forwardly from the first upright portion and coupled to the base.
The
first lower portion is reclinable relative to the base about a first flex
region. A
flexible back support includes a second upright having a second flex region
proximate a lumbar region of the back support, wherein the second upright is
flexible about the second flex region, and a second lower portion extending
forwardly from the second upright and coupled to the first lower portion. The
second lower portion is reclinable with the first lower portion relative to
the base
about the first flex region. The second lower portion has a third flex region
located between the first and second flex regions, wherein the second lower
portion is flexible about the third flex region, and wherein the second
upright is
pivotally coupled to the back frame at a third location spaced above the
second
flex location.
[0015] In another aspect, one embodiment of a body support assembly
includes
a base member and a lower support structure including a longitudinally
extending
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portion coupled to the base member at a first location, the longitudinally
extending
portion defining a first flex region positioned rearward of the first
location. A
front link extends upwardly from the longitudinally extending portion
forwardly of
the first location, wherein at least one of the lower support member and the
front
link define a second flex region positioned forward of the first location. A
rear
link extends upwardly from the longitudinally extending portion rearward of
the
first location. A seat support member is coupled to the front link and to the
rear
link, wherein the seat support member supports a seating surface. At least one
of
the seat support member and the front link define a third flex region and the
seat
support member defines a fourth flex region adjacent the rear link. A rigid
back
frame extends upwardly and rearwardly from the lower support structure,
wherein
the rigid back frame is rigidly connected to the rear link. A flexible back
support
includes an upper portion pivotally connected to the rigid back frame at a
second
location vertically spaced above the seat support and a lower portion rigidly
connected to the rear link. The flexible back support has a fifth flex region
located
between the seat support and the second location and a sixth flex region
located
between the fifth flex region and the rear link.
[0016] In
another aspect, one embodiment of a backrest assembly includes a
back frame including a pair of first uprights and a back support includes a
pair of
second uprights, each of the second uprights positioned laterally outboard of
one
of the first uprights. A body support member is coupled to the back support. A
pair of connectors extend laterally between one of the first uprights and one
of the
second uprights, wherein each of the connectors includes a first connector tab
extending laterally from one of the first uprights and a second connector tab
extending laterally from one of the second uprights, wherein the first and
second
connector tabs are overlapping.
[0017] In
another aspect, one embodiment of a backrest assembly includes a
back frame having a first upright and a back support having a second upright
laterally spaced from the first upright. A body support member is coupled to
the
back support. A connector tab extends laterally from one of the first or
second
upright and includes a laterally extending and non-cylindrical insert portion
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received in a socket formed in the other of the first or second upright. The
insert
portion is rotatable about a laterally extending axis relative to the socket
between
at least first and second pivot positions, wherein the insert portion engages
first
and second stop surfaces of the socket when the insert portion is in the first
and
second positions respectively.
[0018] In another aspect, one embodiment of a support structure for a
body
support member includes a lower support member having an upwardly extending
first post, a backrest frame having an upwardly extending second post, and a
seat
support having a downwardly extending boss structure coupled to the first and
second posts.
[0019] In another aspect, one embodiment of a body support assembly
includes
a seat having opposite sides spaced apart in a lateral direction and a front
and rear
spaced apart in a first longitudinal direction. A back support has opposite
sides
spaced apart in the lateral direction and a top and bottom spaced apart in a
second
longitudinal direction. A support structure supports the seat at a pair of
laterally
spaced front locations and a central rear location, wherein the rear of the
seat is
rotatable relative to the front of the seat about a first longitudinal axis.
The
support structure supports the back support at a pair of laterally spaced
upper
locations and a central lower location, wherein the bottom of the back support
is
rotatable relative to a top of the back support about a second longitudinal
axis. In
one embodiment, the seat and the back support are coupled to a central rear
link at
the central rear location and the central bottom location respectively.
[0020] In another aspect, one embodiment of a body support assembly
includes
a body support member reclinable relative to a base. A recline limiter
assembly
interfaces between the body support member and the base to limit the recline
of
the body support member relative to the base. The recline limiter assembly
includes a recline limiter having at least two rotational degrees of freedom.
[0021] In another aspect, one embodiment of a body support assembly
includes
a body support member rearwardly reclinable relative to a base. The body
support
member has a front and a rear spaced apart in a longitudinal direction. A
recline
stop member includes a first end connected to the body support member and a
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second end defining a stop portion. A recline limiter includes at least first
and
second longitudinally spaced stop surfaces, wherein the plurality of stop
surfaces
are angularly spaced about a longitudinal axis. The recline limiter is
rotatably
mounted to the base about the longitudinal axis, and is rotatable about the
longitudinal axis between a first position, wherein the stop portion engages
the
first stop surface, and a second position, wherein the stop portion engages
the
second stop surface.
[0022] In another aspect, one embodiment of a body support assembly
includes
a lower base and a seat support connected to the lower base with an extensible
support column having an actuation button. A handle is rotatable about a first
lateral axis. A drive gear is connected to the handle and is rotatable about
the first
lateral axis from a non-engaged configuration to an engaged configuration. The
drive gear includes a first plurality of teeth. A driven gear is rotatable
about a
second lateral axis spaced apart from the first lateral axis. The driven gear
includes a second plurality of teeth, wherein the first and second pluralities
of
teeth are not engaged when the drive gear is in the non-engaged position. The
drive gear is rotatable to the engaged configuration whereinafter the first
plurality
of teeth are brought into engagement with the second plurality of teeth after
a first
predetermined amount of rotation of the handle about the first lateral axis.
The
driven gear is rotated from a non-actuated position to an actuation position
about
the second lateral axis when the drive gear is in the engaged configuration.
An
actuator is coupled to the drive gear, wherein the actuator is rotatable into
engagement with the actuation button as the driven gear is rotated to the
actuation
position.
[0023] In another aspect, one embodiment of a backrest assembly includes
a
backrest frame having first and second laterally spaced uprights defining a
central
opening therebetween. Each of the first and second uprights has upper and
lower
portions defining separate first and second forwardly facing convex
curvatures. A
cross member extends between and is coupled to the uprights at the junction
between the upper and lower portions. A suspension material is connected to
the
first and second uprights and spans across the central opening. The suspension
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material has a front surface and a rear surface, wherein at least opposite
side
portions of the suspension material have first and second forwardly facing
convex
curvatures. A laterally extending stay is coupled to and extends between the
rear
surface of the suspension material and the cross member.
[0024] In another aspect, on embodiment of an armrest assembly for a
seating
unit includes an armrest support adapted for attachment to a seating unit and
including an upper support platform. An armrest pad is adapted to support a
person's arm and includes laterally spaced and downwardly extending rim
portions
positioned along opposite sides of the armrest pad. A pair of swing arms each
have a first end pivotally connected to the upper support platform at spaced
apart
first locations and a second end pivotally and slidably connected to the
armrest
pad at spaced apart second locations. The swing arms adjustably support the
armrest pad for independent longitudinal, lateral, and rotational adjustment.
At
least one of the rim portions engages at least one of the swing arms to limit
inboard and/or outboard lateral movement of the armrest pad relative to the
support platform.
[0025] Various methods of using and assembling the body support assembly
and other components are also provided.
[0026] The various embodiments of the body support assembly and
components, and methods for the use and assembly thereof, provide significant
advantages over other body support assemblies and methods. For example and
without limitation, the structure allows for the integration of a suspension
material
into the backrest and/or seat, while maintaining an overall flexibility of
those
components. The structure and user interface provide a body support structure
that adapts to the user's body and provides for macro compliance during use,
while also providing micro compliance at the user interface and avoiding hard
interfaces around the periphery thereof.
[0027] In addition, the various links and flex regions provide a simple
but
robust structure that ensures a proper fit for a multitude of users without
the
requirement of complex mechanical mechanisms and adjustment interfaces. The
body support assemblies, with their various flex regions and material
compliance,
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provide for improved comfort and fit, while reducing costs by reducing and/or
eliminating the overall number of parts, including various metal components,
which may reduce manufacturing costs. In addition, the compliant materials may
reduce the overall weight of the body support assembly, and the attendant
shipping
costs associated therewith. The body support assembly is uncomplicated,
durable,
visually appealing and capable of a long operating life. At the same time,
various
components are ideally suited for interfacing with the compliant seating
structure,
including for example and without limitation the floating recline limiter that
accommodates the movement of a body support member relative to a base.
[0028] The armrest also provides significant advantages, with the rim of
the
pad limiting inboard and outboard movement, such that the underlying platform
remains obscured during lateral movement, thereby improving the aesthetics of
the
armrest.
[0029] The disclosed backrest also provides significant advantages, for
example and without limitation, providing for a single piece of suspension
material to cover a frame having a plurality of separate convex curvatures.
The
stay allows for the suspension material to conform to the backrest, while
pulling it
rearwardly to provide a conforming shape and pleasing aesthetic appearance.
[0030] The foregoing paragraphs have been provided by way of general
introduction, and are not intended to limit the scope of the claims presented
below.
The various preferred embodiments, together with further advantages, will be
best
understood by reference to the following detailed description taken in
conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a perspective view of one embodiment of a body support
assembly.
[0032] FIG. 2 is a right side view of the body support assembly shown in
Figure 1, with the left side view being a mirror image thereof.
[0033] FIG. 3 is front view of the body support assembly shown in Figure
1.
[0034] FIG. 4 is a rear view of the body support assembly shown in Figure
1.
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[0035] FIG. 5 is a bottom view of the body support assembly shown in
Figure
1.
[0036] FIG. 6 is a top view of the body support assembly shown in Figure
1.
[0037] FIGS. 7A, B and C are partial cross-sectional views of a body
support
member.
[0038] FIG. 8 is a partial perspective view of a seat without the textile
material
shown for the sake of illustrating the underlying components.
[0039] FIG. 9 is a top view of one embodiment of a seat support structure
without the textile material or carrier frame shown for the sake of
illustrating the
underlying components.
[0040] FIG. 10 is a bottom perspective view of one embodiment of a lower
seat support platform.
[0041] FIG. 11 is a right side view of the support platform shown in
Figure 10
with a left side view being a mirror image thereof.
[0042] FIG. 12 is a rear view of the support platform shown in Figure 10.
[0043] FIG. 13 is a top view of the support platform shown in Figure 10.
[0044] FIG. 14 is a left side view of one embodiment of a support ring,
with a
right side view being a mirror image thereof.
[0045] FIG. 15 is atop view of the support ring shown in Figure 14.
[0046] FIG. 16 is a side view of one embodiment of an upper seat shell.
[0047] FIG. 17 is a top view of the upper shell shown in Figure 16.
[0048] FIG. 18 is a schematic side view illustrating flexing of the seat
assembly during recline.
[0049] FIG. 19 is a schematic front view illustrating flexing of the seat
assembly during recline.
[0050] FIG. 20 is an exploded view of a seat assembly.
[0051] FIG. 21 is a schematic view showing a four-bar mechanism
supporting
a seat assembly.
[0052] FIG. 22 is a rear perspective view of second embodiment of a body
support assembly.
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[0053] FIG. 23 is a front perspective view of the body support assembly
shown
in Figure 22.
[0054] FIG. 24 is a front view of the body support assembly shown in
Figure
22.
[0055] FIG. 25 is a right side view of the body support assembly shown in
Figure 22, with the left side view being a mirror image thereof with the
exception
of the actuator controls.
[0056] FIG. 26 is a rear view of the body support assembly shown in
Figure
22.
[0057] FIG. 27 is a top view of the body support assembly shown in Figure
22.
[0058] FIG. 28 is a bottom view of the body support member shown in
Figure
22.
[0059] FIG. 29 is a front perspective view of a third embodiment of a
body
support assembly.
[0060] FIG. 30 is a rear perspective view of the body support assembly
shown
in Figure 29.
[0061] FIG. 31 is a right side view of the body support assembly shown in
Figure 29.
[0062] FIG. 32 is a front view of the body support assembly shown in
Figure
29.
[0063] FIG. 33 is a left side view of the body support assembly shown in
Figure 29.
[0064] FIG. 34 is a rear view of the body support assembly shown in
Figure
29.
[0065] FIG. 35 is a top view of the body support assembly shown in Figure
29.
[0066] FIG. 36 is a bottom view of the body support member shown in
Figure
29.
[0067] FIGS. 37 and 38 are right and left side views of a fourth
embodiment of
a body support assembly.
[0068] FIG. 39 is a right side view of a back support.
[0069] FIG. 40 is a perspective view of the back support shown in Figure
39.
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[0070] FIG. 41 is a top view of the back support shown in Figure 39.
[0071] FIG. 42 is a bottom view of the back support shown in Figure 39.
[0072] FIG. 43 is an enlarged, partial side view of the body support
assembly
shown in Figure 37.
[0073] FIG. 44 is a partial, cross-sectional view of a front portion of a
seat
assembly.
[0074] FIG. 45 is a partial, cross-sectional view of a side portion of a
seat
assembly.
[0075] FIG. 46 is a partial, cross-sectional view of a top portion of a
back
support.
[0076] FIG. 47 is a partial, cross-sectional view of a side portion of a
back
support.
[0077] FIG. 48 is a partial front view of a connection between the back
frame
and the back support.
[0078] FIG. 49 is a partial front view of a connection between the back
frame
and the back support.
[0079] FIG. 50 is a partial, cross-sectional view of the connection
between the
back frame and back support taken along line 50-50 of Figure 48.
[0080] FIG. 51 is an exploded view of the connection between the back
frame
and back support.
[0081] FIG. 52 is a partial, side view of the back frame connector.
[0082] FIG. 53 is a cross-sectional view of a cross member and a stay
coupled
thereto with a textile material in an assembled configuration.
[0083] FIG. 54 is a cross-sectional view of a stay and textile material
in a
preassembly configuration.
[0084] FIG. 55 is a flow diagram illustrating the assembly of the seat
assembly.
[0085] FIG. 56 is a partial, plan view of a textile material installed on
the seat
assembly and back support.
[0086] FIG. 57 is a rear perspective view of a back support with a lumbar
connected thereto.
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[0087] FIG. 58 is a front view of the back support and lumbar shown in
Figure
57.
[0088] FIG. 59 is a partial, enlarged front view of the back support and
lumbar
connection.
[0089] FIG. 60 is an exploded view of an armrest assembly.
[0090] FIG. 61 is a partial, longitudinal cross-sectional view of the
armrest
assembly shown in Figure 60.
[0091] FIG. 62 is a partial, lateral cross-sectional view of the armrest
assembly
shown in Figure 60.
[0092] FIGS. 63 and 64 show maximum fore-aft adjustments of the armrest
assembly shown in Figure 60.
[0093] FIGS. 65 and 66 show maximum side-to-side adjustments of the
armrest assembly shown in Figure 60.
[0094] FIGS. 67 and 68 show maximum inward angular adjustments of the
armrest at maximum fore-aft positions.
[0095] FIGS. 69 and 70 show maximum outward angular adjustments of the
armrest at maximum fore-aft positions.
[0096] FIG. 71 is a top view of a control assembly.
[0097] FIG. 72 is a cross-sectional view of a rotatable recline limiter
engaged
by a linear rack.
[0098] FIG. 73A-C are exploded partial views of the control assembly.
[0099] FIG. 74 is an end view of the back support connector tab.
[00100] FIG. 75 is an end view of the back frame connector tab.
[00101] FIG. 76 is a schematic cross-sectional view showing the
rotational
limiter between the back frame and back support.
[00102] FIG. 77 is an exploded partial view of the tilt control assembly
with
a recline limiter, energy boost and height adjustment control.
[00103] FIG. 78 is a cross-sectional view of the tilt control assembly,
recline
limiter, energy boost and height adjustment control.
[00104] FIG. 79 is a cross-sectional view of the tilt control assembly,
recline
limiter and energy boost taken along line 79-79 of Figure 78.
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[00105] FIG. 80 is a perspective view of the recline limiter, energy
boost and
height adjustment control assembly.
[00106] FIG. 81 is an exploded view of the recline limiter, energy boost
and
height adjustment control assembly.
[00107] FIGS. 82A-D are end views of the recline limiter and energy
boost in
a no-recline position, a mid-recline/mid-boost position, a full recline/full
boost
position, and a full recline/no boost position respectively.
[00108] FIGS. 83A and B are top and bottom perspective views of a rear
link
connector.
[00109] FIGS. 84A-D are a bottom, top, exploded and enlarged cross-
sectional views showing the connection between a front link and the seat
assembly.
[00110] FIG. 85 is a partial view of one embodiment of a stay.
[00111] FIG. 86 is a partial cut-away view of a seat assembly.
[00112] FIG. 87A and B are views showing a drive gear and driven gear in
non-engaged and engaged positions respectively.
[00113] FIG. 88 is a front perspective view of a support frame.
[00114] FIG. 89 is a rear perspective view of a carrier frame.
[00115] FIG. 90 is a partial, front perspective view of an alternative
embodiment of a carrier frame.
[00116] FIGS.91A and B are perspective views of alternative embodiments
of armrest assemblies.
[00117] FIG. 92 is a perspective view of an alternative embodiment of a
carrier frame.
[00118] FIG. 93 is a bottom perspective view of a lower support
structure.
[00119] FIG. 94 is a top perspective view of the lower support structure
shown in Figure 93.
[00120] FIGS. 95A-E are cross-sectional views of the lower support
structure
taken along corresponding lines shown in Figure 94.
[00121] FIG. 96 is a front perspective view of a lumbar support.
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[00122] FIG. 97 is a front perspective view of the lumbar support shown
in
Figure 97 with the sleeve removed.
[00123] FIG. 98 is a perspective view of a lumbar support adapter.
[00124] FIGS. 99A and B are rear views of a chair with a lumbar support
applied thereto in an upper and lower position respectively.
[00125] FIG. 100 is a partial, perspective view of a backrest with a
headrest
applied thereto.
[00126] FIG. 101 is a partial side view of the backrest shown in Figure
100.
[00127] FIG. 102 is an exploded view of the headrest assembly shown in
Figures 100 and 101.FIG. 103 is a partial cross-sectional view of the
interface
between a lower support and a back support.
[00128] FIG. 104 is an end view of a recline limiter and energy boost
limiter.
[00129] FIG. 105 is a cross-sectional view of the tilt control assembly,
recline
limiter, energy boost and height adjustment control.
[00130] FIGS. 106A-D are end views of the recline limiter and energy
boost
in a no-recline position, a mid-recline/mid-boost position, a full
recline/full boost
position, and a full recline/no boost position respectively.
[00131] FIG. 107 is atop view of a tape configuration.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED
EMBODIMENTS
[00132] It should be understood that the term "plurality," as used
herein,
means two or more. The term "longitudinal," as used herein means of or
relating
to a length or lengthwise direction 2, 2', for example a direction running
from the
bottom of a backrest assembly 6 to the top thereof, or vice versa, or from the
front
of a seat assembly 8 to the rear thereof, or vice versa. The term "lateral,"
as used
herein, means situated on, directed toward or running in a side-to-side
direction 4
of a body support assembly 10, shown in one embodiment as an office chair
including the backrest assembly 6 and seat assembly 8. It should be understood
that the body support assembly may be configured as any structure that
supports a
body, including without limitation automotive, aircraft and mass-transit
seating,
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beds, home furnishings (including sofas and chairs), and other similar and
suitable
structures. In one embodiment of a backrest assembly disclosed below, a
lateral
direction 4 corresponds to a horizontal direction and a longitudinal direction
2
corresponds to a vertical direction, while in one embodiment of a seat
assembly,
the longitudinal direction 2' corresponds to a horizontal direction. The
lateral
direction 4 may be referred to as an X direction, while the longitudinal
direction 2,
2' refers to a Y direction and a Z direction is orthogonal to the body support
surface of both the backrest and seat assemblies 6, 8.
[00133] The term "coupled" means connected to or engaged with, whether
directly or indirectly, for example with an intervening member, and does not
require the engagement to be fixed or permanent, although it may be fixed or
permanent. The terms "first," "second," and so on, as used herein are not
meant to
be assigned to a particular component so designated, but rather are simply
referring to such components in the numerical order as addressed, meaning that
a
component designated as "first" may later be a "second" such component,
depending on the order in which it is referred. It should also be understood
that
designation of "first" and "second" does not necessarily mean that the two
components or values so designated are different, meaning for example a first
direction may be the same as a second direction, with each simply being
applicable to different components. The terms "upper," "lower," "rear,"
"front,"
"fore," "aft," "vertical," "horizontal," "right," "left," and variations or
derivatives
thereof, refer to the orientations of an exemplary body support assembly 10,
shown as a chair in FIGS. 1-6 and 22-36, from the perspective of a user seated
therein. The term "transverse" means non-parallel. The term "outwardly" refers
to a direction facing away from a centralized location, for example the phrase
"radially outwardly" refers to a feature diverging away from a centralized
location,
for example the middle or interior region of a seat or backrest, and lies
generally in
the X Y plane defined by the lateral and longitudinal directions 2, 2', 4. It
should
be understood that features or components facing or extending "outwardly" do
not
necessarily originate from the same centralized point, but rather generally
emanate
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outwardly and exteriorly along a non-tangential vector. Conversely, the term
"inwardly" refers to a direction facing toward the centralized or interior
location.
[00134] The term "textile material" refers to a flexible material made
of a
network of natural or artificial fibers (yarn, monofilaments, thread, etc.).
Textile
materials may be formed by weaving, knitting, crocheting, knotting, felting,
or
braiding. Textile materials may include various furniture upholstery
materials,
which may be used for example to cover a foam cushion, and/or suspension
materials, which may be stretched or put in tension across an opening to
support a
user.
BODY SUPPORT ASSEMBLY:
[00135] Referring to FIGS. 1-6, 22-36 and 77, the body support assembly
10
is shown as including a tilt control assembly 18, also referred to as a lower
support
structure, a base structure 12 and the backrest and seat assemblies 6, 8. In
one
embodiment, the base structure 12 includes a leg assembly 14 and a support
column 16 coupled to and extending upwardly from the leg assembly. The tilt
control assembly 18 is supported by and coupled to atop of the support column
16. The leg assembly may alternatively be configured as a fixed structure, for
example a four legged base, a sled base or other configuration. In one
embodiment, the support column 16 may be height adjustable, including for
example and without limitation a telescopic column with a pneumatic, hydraulic
or
electro-mechanical actuator. The leg assembly 14 includes a plurality of
support
legs 22 extending radially outwardly from a hub 24 surrounding the support
column. Ends of each support leg may be outfitted with a caster, glide or
other
floor interface member 20.
ARMREST ASSEMBLY:
[00136] In the embodiment of FIGS. 1-6, a pair of armrest assemblies 26
are
coupled to the tilt control assembly 18. Various user interface controls 28
are
provided to actuate and/or adjust the height of the seat, including for
example an
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actuation lever pivotally coupled to the armrest assembly, or to control the
tension
and/or return force of the tilt control assembly 18, as further disclosed
below.
[00137] Referring to FIGS. 22-36, 91A and B, another embodiment of an
armrest assembly 300 is coupled to the base structure 12. The armrest assembly
includes a base portion 302 disposed above the support column 16, and
positioned
between the base structure and seat assembly 6, and in particular above a
longitudinally extending portion, or base link 33, of a lower support
structure 18.
A platform 402 supports the tilt control assembly 18, including a housing 422,
which has a hub portion 405 receiving the support column. 16. A cover 900
extends around the housing, with the base portion 302 disposed on top of the
cover
900 and covering the housing 522. The base portion 302 is coupled to the
platform with one or more fasteners, shown as bolts, which clamp the housing
422
and lower portion 400 of the tilt control assembly 18 therebetween..
[00138] The base portion 302 includes a pair of laterally extending arms
304
disposed between and extending laterally outwardly (vector having portion
along
axis 4) and rearwardly (vector having portion along axis 2') from the lower
support structure 18 and the seat assembly 6, including a seat support member
308, and defining an angle a relative to the lateral direction 4 as shown in
FIG. 28.
The base includes an upwardly protruding curved or flared portion 423, which
overlies the housing 422 at the rear portion thereof. The armrest assembly
further
includes a pair of upright portions 306 connected to the laterally extending
arms
304 and extending upwardly along opposite sides of the seat assembly 6 and
seat
support member 308 as shown in FIG. 28. The pair of laterally extending arms
304 in combination have a V-shaped configuration when viewed from above as
shown in FIG. 28, while the armrest assembly 300 has a U-shape when viewed
from the front or rear of the body support assembly as shown in FIGS. 24 and
26.
The armrest assembly 300 is rotationally fixed relative to the base 12 about a
lateral axis, but rotates with the seat assembly 6 about a vertical axis 310
and
moves vertically with the support column 16. The armrest assembly 300 does not
tilt with the seat and/or backrest assembly, which are moveable from an
upright,
nominal position to one or more reclined positions relative to the armrest
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assembly. It should be understood that the chair may be configured without any
armrests on either side, as shown for example in FIGS. 37 and 38. If the
armrest
assembly is omitted, a cover 421, shown in FIG. 73A, may be bolted to the
platform 402 over the housing 422 and cover 900.
[00139] Referring to FIGS. 22, 24, 25, 60-70 and 91B, the upright
portions of
the armrest assembly define an armrest support supporting a height adjustable
upper arm 312 having an upper support platform 314. An actuation button 321
may be depressed to allow the upper arm 312 to move vertically relative to and
within the upright portion 306. In an alternative embodiment shown in FIG.
91A,
the armrest is not height adjustable, but rather has an upper arm 323 at is
flush
with and coupled to the upright portion 306. A pair of stops 316, shown as
protuberances or posts, extend upwardly from the support platform 314 adjacent
opposite sides of the platform 314, with an outboard stop 316 being
longitudinally
displaced rearwardly relative to an inboard stop such that the stops 316 are
diagonally positioned along an axis 329 forming an angle B relative to a
longitudinal axis 317.
[00140] An armrest pad 318 is adapted to support a person's arm is
coupled to
the support platform. The armrest pad 318 has a base 320 with laterally spaced
and downwardly extending rim portions 322 positioned along opposite sides of
the
armrest pad. In one embodiment, the rim portion 322 extends around an entire
periphery of the base 320. The base 320 is preferably configured as a plastic
plate.
A pair of swing arms 324, 326 are provided, with each swing arm having a first
end 328, 330 pivotally connected to the upper support platform with a pair of
fasteners 332, configured as a screws with washers, that engage openings at
spaced apart first locations 334, 336. The locations are spaced apart along
the
longitudinal axis 317. The swing arms 324, 326 each have a second end 338, 340
pivotally and slidably connected to the armrest pad 318 with a pair of
upwardly
extending boss structures 342, 344, or studs, having ends engaged by fasteners
350, 352 at spaced apart second locations 346, 348, which move relative to the
first locations. The second location 342 is spaced forwardly of the first
location
334 while the second location 348 is space rearwardly of the first location
344
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when the arm pad is in a nominal position as shown in FIG. 61. The swing arms
324, 326 adjustably support the armrest pad for independent longitudinal,
lateral,
and rotational adjustment, meaning the armrest pad may be moved along and/or
transverse to the longitudinal axis 317, as well as rotated about an axis
normal to
the plane defined thereby as further explained below.
[00141] As shown in FIGS. 60, 61, 65 and 66, at least one of the side
rim
portions 322 has an inner side surface 358, 360 that engages the side surface
354,
356 of at least one of the swing arms 324, 326 to limit inboard and outboard
lateral
movement of the armrest pad 18 relative to the support platform 314. The pad
base 320 has a pair of longitudinally spaced and longitudinally extending
slots
364, 366, with the second ends of the pair of swing arms, and the boss
structures
342, 344 in particular, disposed through the slots 364, 366. The boss
structures
342, 344 are pivotally and translatably/slidably connected relative to the pad
base
320 along the slots 364, 366. As shown in FIGS. 60, 63 and 64, the boss
structures 342, 344 bottom out at the ends of the slots 364, 366 to limit the
fore-aft
travel of the armrest pad 318 relative to the support platform 314. The
fasteners
350 have enlarged head portions, which function as a pair of guides 351 that
are
coupled to the second ends 338, 340 of the pair of swing arms and are disposed
on
top of the pad base within a recessed portion 365, 367 surrounding the
periphery
of the slots 364, 366, with the guides 351 providing for relative
translation/sliding
and rotation of the pad base 320 relative to the swing arms 324, 326.
[00142] The armrest pad includes a plate 368, preferably steel, having a
longitudinal track 370 running along the bottom of the plate 368 and formed by
a
raised portion of the plate. The track 370 defines a channel overlying the
fasteners
350, with a width and depth dimensioned to accommodate the fasteners 350
within
the channel and thereby allowing slidable movement of the arm cap 318 in a
longitudinal direction 317 as the bosses 342, 344 move in the slots 364, 366
and
the fasteners 350 move in the track 370. The plate 368 is coupled to the base
320
with a plurality of fasteners 391, shown as six, with the fasteners 350
trapped
between the base 320 and plate 368 and moveable in the recesses 365, 367 and
the
track 370. The interaction between the rotatable swing arms 324, 326 and the
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slideable/translatable armrest pad 318 allows the armrest pad 318 to be moved
to a
number of different positions relative to the support platform 314. In
particular,
the armrest pad 318 is moveable from a nominal position, designated as armrest
pad 318', to an infinite number of positions, including: (1) maximum inwardly
turned angles 0, (e.g. 31.5 degrees in one embodiment) at rear and forward
location (FIGS. 67 and 68), (2) maximum outwardly turned angle (f) (e.g., 31.9
degrees in one embodiment) at a rear and forward locations (FIGS. 69 and 70),
(3)
nominal fore aft extremes (FIGS. 63 and 64), having a total travel of 62.52 mm
in
a longitudinal direction (47.24 mm rearward and 15.28 mm forward), and (4)
side-
to-side extremes (FIGS. 65 and 66), having a total travel of 46 mm (25mm
outboard and 21 mm inboard). The stops 316 engage stops 382, 384 formed on
peripheral edge of the swing arms 324, 326 to limit the maximum inward and
outward angular adjustments as shown in FIGS. 60 and 67-70.
[00143] In operation, the fasteners 350, or guides 351, are moveably
disposed
in the track 370 between the plate 368 and base 320, such that the plate 368
and
base 320 are slidable relative to the support platform 314 as shown in FIGS.
63, 64
and 67-70. A foam pad 372 is disposed on top of the plate 368. A cover 374 is
disposed over the foam pad and has a peripheral edge portion 376 surrounding
the
foam pad and plate to secure the foam pad 372 to the plate 368 and complete
the
assembly of the armrest pad 318. A lip 378, or insert portion, extends
laterally and
radially inwardly from the edge portion 376 and is disposed between the plate
368
and the pad base 320. In one embodiment, the cover 374 is made of a urethane
material.
[00144] The downwardly extending rim 322, which acts as a stop that
engages the sides 354, 356 of the swing arm(s) to limit the amount of side-to-
side
travel, prevents the platform 314 and swing arms 324, 326 from being exposed
to
view during use. As shown in FIGS. 65 and 66, the armrest pad 318 overlies and
covers the upper surface of the support platform 314 in the maximum side-to-
side
extremes, and referring to FIGS. 63-70, overlies and covers the upper surface
of
the support platform 314 in virtually all positions of the armrest pad,
including the
side-to-side and front-to-back maximum extremes, with the exception of a small
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portion of the support platform being visible in a maximum in-turned positions
at
fore and aft locations as shown in FIGS. 67 and 68, and the out-turned
position of
FIG. 69.
TILT CONTROL ASSEMBLY:
[00145] Referring to FIGS. 1-6, 22-38, 43, 77, 78, and 83A-84D, the
backrest
and seat assemblies 6, 8 are operably coupled to the tilt control assembly 18,
or
lower support structure, which controls the movement thereof, for example
during
recline. One embodiment of a suitable tilt control assembly is disclosed in
U.S.
Patent No. 9,826,839, entitled "Chair Assembly with Upholstery Covering," the
entire disclosure of which is hereby incorporated herein by reference. The
tilt
control assembly may include a plurality of rigid control links, which may be
mechanically connected, for example via pivot pins, to form a linkage
assembly,
including for example a four-bar linkage.
[00146] In other embodiments, the tilt control assembly include
integrally
formed links 23, 25, 33, configured for example with strategic deformable
locations that allow for predetermined deformations and define "flex regions,"
otherwise referred to as "flex joints," or virtual pivot locations. The
various
configurations of the links and flex regions may be configured as shown and
disclosed in U.S. Pub. No. 2016/0296026 Al, entitled "Seating Arrangement,"
and
in U.S. Pub. No. 2018/0352961, entitled "Seating Arrangement and Method of
Construction," the entire disclosures of which are hereby incorporated herein
by
reference.
[00147] For example, the tilt control assembly 318 may be configured as
a
four-bar mechanism as shown in FIGS. 21 and 43, with a bottom, or base link 33
connected to the base structure 12 at a first location, and front and rear
links 23, 25
connected between the base link and the seat assembly 8. The base, front and
rear
links 33, 23, 25 define the lower support structure. For example, the front
and rear
links 23, 25 may be pivotally or bendably connected to the base link 33 at
flex
regions 29, 31, whether integrally formed or otherwise. The front and rear
links
23, 25 may also be pivotally, or bendably connected to the seat assembly 8 at
flex
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regions 27, 53, with the portion 57 of the seat assembly extending between the
flex
regions 27, 53 defining a link of the four-bar mechanism. The flex region 53
is
formed in the support platform 30 portion of the seat assembly as explained in
more detail below. The various flex regions 27, 29, 31, 53 may be formed as
living hinges, or thin flexible hinges made from the same material as the two
more
rigid pieces the living hinge connects, so as to provide for relative rotation
or
pivoting between the more rigid pieces by bending of the living hinge. It
should
be understood that in alternative embodiments, the links and bars of the
mechanism may also be configured as rigid links and bars connected at fixed
hinge points.
[00148] In one embodiment, and referring to FIGS. 37, 38, 43, 78, and 93-
95E, the tilt control assembly 318, or lower support structure, includes a
longitudinally extending portion 400 that extends fore aft along the
longitudinal
axis 2', and which defines the base link 33. The longitudinally extending
portion
400 is supported by the platform 402, configured as a plate member, with an
opening that receives the hub portion 405 of the housing 422, positioned at a
first
location 406. The hub is shaped to receive the upper end of the support column
16, which extends through the opening. The portion 400 has a recess 403
defined
in the bottom thereof as shown in FIGS. 93 and 95B, with a thinner central
portion
405 and thicker outboard portions 509, with the platform 402 disposed in the
recess 403.
[00149] The pair of laterally spaced front links 23 extend upwardly and
forwardly from the longitudinally extending portion 400 at a location 408
positioned forwardly of the first location 406. The front links 23 have a
maximum
lateral width (W1), defined by the laterally spaced outboard edges thereof, as
shown in FIG. 24. The rear link 25 also extends upwardly and forwardly from
the
longitudinally extending portion 400, but at a location 410 positioned
rearwardly
of the first location 404. The rear link 25 has a maximum lateral width
defined by
the laterally spaced outboard surfaces thereof, which is substantially equal
to the
width (W3) of the lower support 226 of the back support 212, as shown in FIG.
42.
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[00150] The lower support structure may be referred to as a lower shell,
with
the longitudinally extending portion 400, front link 23, and in one embodiment
a
portion of the rear link 25, defining an integrally formed structure, which
define in
turn two or three integrally formed bars (or portions thereof) of the four bar
linkage. The lower support structure 400 has strategically positioned tensile
substrates 1220, 1222 (shown in FIG. 107), made for example of glass
reinforced
tape, to accommodate bending and deformation of the structure at the flex
regions
29, 31. Strategic locations on the lower support structure are provided with
specific geometries that allow for predetermined deformations and define the
flex
regions 29, 31, otherwise referred to as "flex joints," or virtual pivot
locations.
As shown in FIG. 107, the tensile substrate 1222 has a "H" shape with
elongated
side portions having a greater longitudinal length than a central portion
thereof.
The "H" helps to ensure that the side portions may extend further along the
curved
transition portion. In one embodiment, the substrates 1220, 1222 are coupled
to a
central connector body 1224, as shown in FIG. 107, with the subassembly of the
connector body 1224 and substrates 1220, 1222 then overmolded with an outer
body to define the lower support structure 400, front links 23 and post 407.
The
substrates 1220 are in-molded along the bottom portion of the front feet of
the
central connector body, while the substrate 1222 is disposed on top of the
rear feet
of the connector body, such that the substrates are properly located to
undergo
tension during recline and use of the chair. The method of making the
reinfbrced
support structure further includes positioning a tape carrier having exposed
first
and second sections of glass fiber tape 1220, 1222 in a mold in a manner such
that
the first and second sections of tape are spaced apart in different planes
within the
mold, and molding a shell over the tape carrier and first and second sections
of
tapeõ wherein the first section of tape is positioned adjacent an upper
surface of the
shell and the second section of tape is positioned adjacent a lower surface of
the
sheil. The various configurations of the links and flex regions may be
configured
as shown and disclosed in U.S. Pub. No. 2016/0296026 Al, entitled Seating
Arrangement, and U.S. Pub. No. 2018/0295996A1, entitled Seating Arrangement,
the entire disclosures of which are hereby incorporated herein by reference.
The
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phrase "flex region" refers to a portion of the structure that allows for
flexing or
bending in the designated region, through elastic deformation, thereby
allowing or
providing for relative flexing movement (e.g., pivoting or bending) of the
component or structure on opposite sides of the flex region, thereby defining
a
virtual pivot location, for example a horizontal pivot axis, with the
understanding
that the virtual pivot axis may move during the flexing, rather than being
defined
as a hard fixed axis.
[00151] For
example, as shown in FIGS. 21, 24, 25, 84A-D, 93, 94 and 95D
and E, front links 23 may each be configured as a blade 412, having a lateral
width
and thickness, both of which may vary. In one embodiment, each of the blades
has a greater thickness along a longitudinal centerline thereof, with the
blade
having an elliptical cross section. As shown in FIGS. 95D and E, the inboard
edge
of the blade may taper or be thinner, while the outer edges are curved. The
front
links have a general "S" shape, with an upper end portion 414 defining a
flange
with a plurality of boss structures or insert portions extending upwardly from
the
flange. A flex region 27 may be formed in the front links, in the
longitudinally
extending portion 57, or at the junction between the front link 23 and portion
57,
or may be defined by any combination thereof. For example, in various
embodiments, the front link 23 or the longitudinal portion may have a thinner
cross-sectional area defining the flex region, thereby allowing the front link
23 to
pivot relative to the longitudinally extending portion 57 of the seat, for
example
during recline. Tensile substrates 1220 may be positioned along a bottom of
the
longitudinally extending portion 400 extending forwardly from the first
location
406 and along the bottom of the front links 23, with the bottom portions of
those
structures being put in tension during bending as the body support assembly
reclines, and with the upper portions of those structures being put in
compression.
It should be understood that the front links 23 themselves may also bend and
deform elastically during rearward recline of the body support assembly, but
with
the majority of the elastic deformation intentionally occurring at the flex
regions.
In one embodiment, the flex region 29 is formed by making the blade 412
thinner
than the surrounding regions, and also making the blade flat or planar across
the
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width of the blade at the flex region. For example, in one embodiment, flex
region
29 has a length of about 25 mm and a depth of about 2.8 mm, with adjacent
regions of the blade having a thickness of 2 to 3 times the thickness of the
blade in
the flex region 29. In other words, the flex region 29 is introduced by making
the
blade thin and flat. As such, the flex region has a lesser area moment of
inertia,
and is less capable of resisting bending, than the adjacent regions. The
portion
400 is relatively thick between location 406 and the flex region 29, as shown
in
FIG. 95C, but may have a greater thickness along a longitudinal centerline
thereof,
with the portion 400 having a generally elliptical cross section.
[00152] The rear link 25 is relative rigid or stiff, meaning the rear
link does
not bend or deform elastically during rearward recline of the body support
assembly. Rather, the longitudinally extending portion 400 has a thinner
region
defining a flex region 31 immediately adjacent to and in front of the rear
link 25
and the location 410, but rearward of the first location 406. As with flex
region
28, the flex region 31 is defined by a thin and flat cross section, shown in
FIGS. 94
and 95A, having a length of about 25 mm in one embodiment and with the
surrounding regions, for example the adjacent rear portion 401 of portion 400
of
base link 33, having a thickness of 2-5 times greater than the thickness of
the flex
region 31. The rear portion 401 of the longitudinally extending portion 400
positioned between the first location 406 and the rear link 25 may have a
tensile
substrate 1222 positioned in an upper portion thereof, since that portion or
upper
surface will undergo a tensile loading during recline as bending forces are
applied,
and with the lower portion or surface experiencing compression loading.
[00153] The rear portion 401 of the lower support structure 400 extends
rearwardly from the first location 406 and includes an upwardly extending
centrally located arm or post 407 defining in part the rear link 25, and a
flange 409
on each side of the post defining a rear edge 416 as shown in FIGS. 43, 77 and
78.
As explained in more detail below, a back frame 210 and a back support 212
also
have feature defining in part the rear link 25, together with a connector 479
joining
the various features. The back frame 210 and back support 212 therefore pivot
about a common axis defined by the rear flex region 31. The flanges 409 are
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received in a groove 411 defined by a lower portion 214 of a back frame, with
the
groove having a opening with a wider mouth that is tapered rearwardly as shown
in FIG. 103, such that the flanges 409 may pivot slightly relative to the
lower
portion and roll along the lower surface of the support defining the mouth of
the
groove 411 so as to reduce stress risers at the junction thereof.
[00154] In operation, a user can move or recline the backrest and seat
assemblies 6, 8 from an upright position to a reclined position by flexing the
four
bar mechanism, including portions of the seat assembly. It is contemplated
that
the four-bar linkage arrangement as used and described herein is inclusive of
linkage arrangements comprising additional linkage members, such as five-bar
linkage arrangements, six-bar linkage arrangements, and the like. In various
embodiments, the thickness of one or more links 23, 25, 33, 57, and especially
the
front, base and seat links 23, 33, 57, and predetermined flex regions thereof,
may
be located to achieve a desired performance characteristic, including for
example,
the flexibility of the link. Further, in certain embodiments, the thickness of
a link
may vary along the length and/or width of the link to achieve a desired
flexibility
or rigidity across the link or in a localized portion of the link, for example
at flex
regions 27, 28, 31 and 53. In addition, and for example, the front links and
seat
assembly link may be more flexible than the rear link 25 to achieve the
desired
flexibility of the four-bar linkage. In some embodiments, the various links
may be
more flexible in a particular portion or localized area of the link such that
the links
are generally flexible in the localized area and are generally not flexible or
less
flexible in any other area of the link. It is noted that the relative areas of
reduced
thickness may extend along a short distance or the majority of the length of
the
associated link depending upon the support and bending characteristics
desired.
[00155] The spacing W1 between the outermost portions of the front links
23
support provides relative stability to the front portion of the seat, with the
links 23
thereby resisting rotation or torsional movement about the longitudinal axis
2. In
contrast, the centrally located rear link 25 having an overall width W3 is the
only
support for the rear of the seat assembly, which allows for a greater amount
of
rotation or torsional movement of the rear of the seat about the longitudinal
axis 2
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relative to the front of the seat, with the rotation or torsional movement of
the front
of the seat being restricted by the front links 23. In one embodiment, W1 is
about
290-300mm, while W3 is about 140mm, with the ratio between W1 and W3 being
about 2:1.
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RECLINE LIMITER AND ENERGY BOOST:
[00156] Referring to FIGS. 71-73C, 77-82D, 104 and 106A-D, a control
module 420 limits the amount the seat and backrest assemblies 8, 6 may
recline,
while also providing supplemental energy to return the seat and back to an
upright
position. Because the front and rear links 23, 25 are oriented/angled
forwardly, as
the user reclines, the seat 6 is lifted, which provides an automatic
resistance to
recline (or weight activated mechanism). Specifically, the flex zone 27 is
positioned forwardly of the flex zone 29 and the flex zone 53 is positioned
forwardly of the flex zone 31 in a nominal, at-rest position. As such, the
chair can
resist recline without any auxiliary spring and will return to an upright
position
from a recline position when the user exits the chair. Likewise, due to the
compliant nature of the tilt control mechanism 318, seat support and backrest,
those components may bend or elastically deform in response to a load, thereby
absorbing energy through elastic deformation. For some users, however, a
supplemental energy system is helpful to boost resistance to recline. In one
embodiment, the system may be adjusted to provide a no-recline stop, a mid-
boost/mid-stop, a full-boost/full-recline stop, and a no-boost/full-recline
stop.
[00157] The control module 420 includes a housing 422, having a base
426,
made from a casting in one embodiment. A ball retainer housing 428 is made of
two pieces, which are connected to defining a spherical interior socket 424. A
cover 421, or base portion 302 of the armrest assembly, is secured to the top
of the
base 426 with fasteners 505 to further define the housing 422. The retainer
housing 428 is inserted into the base 426 beneath a shroud 516 formed in the
housing, wherein it is secured with a shaft 462. The housing 422, or hub
portion
405 thereof, defines an opening 503 in a bottom wall thereof that receives a
top of
the support column 16, with the housing 422 fixedly secured to the platform
402,
for example with fasteners 505. A ball shaped recline limiter 430, configured
in
one embodiment as a spherical bearing, is rotatably supported in the socket
424 of
the ball retainer housing. The recline limiter 430 is rotatable relative to
the
housing 428 about a longitudinal axis 432. A recline stop member 434,
configured with a rod 436, or portion of a T-shaft, being axially disposed
through
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a spring bushing 438 and spring 446. A cross member 440 of the T-shaft moves
in
a longitudinal slot 442 formed in the side walls of the spring bushing. The
ends of
the cross member 440 extend radially outwardly from the sides of the spring
bushing such that the ends are exposed for engagement with various stop
surfaces
of the recline limiter. The spring bushing 438 has a first end 448 coupled to
a
tension spring 446, for example with a threadable engagement. The spring
bushing 438 includes a pair of tabs 444 extending radially outwardly from
opposite sides thereof. In this way, the ends of the cross member 440 and the
tabs
444 on the spring bushing define different stop members, which engage
different
stop surfaces 450, 452, 454 formed interiorly in, or along a forward end/front
surface of, the spherical bearing, or recline limiter. The surfaces 450, 452
and 454
are spaced apart in a longitudinal direction, with the surface 450 being a
forwardmost surface and the stop surface 454 being a rearwardmost surface. The
surface 452 may be defined as the forward end surface of the ball shaped
recline
limiter, or may be spaced longitudinally reawardly of such a surface so as to
provide contact with the tabs 444 of the spring bushing 438 during all
operations
of the limiter. The recline limiter 430 includes a through opening 453, with
the
spring bushing 438 and stop member rod 436 extending through the opening, and
with the rod 436 extending through a longitudinal center of the spring bushing
438
and spring 446, which are disposed around the rod 436. In the embodiment shown
in FIGS. 104 and 105, the recline limiter 430 is supported at both ends by the
spring bushing 438, which includes radially extending tabs 444 or feet that
support
the recline limiter 430 during rotation. In this embodiment, the tabs 444
extend
further in the longitudinal direction, and also have a greater circumferential
length,
i.e., extend a greater circumferential distance around the spring bushing 438.
The
outer surface of the tabs 444 or feet engage and support the inner bore of the
recline limiter 430 in all positions of the recline limiter such that the
recline limiter
is more stable. An opposite end 456 of the rod is fixedly connected to a T-
shaped
bushing 458 by way of interior threads on the bushing 458 and external threads
on
the end of the rod. Cross members 471 of the bushing 458 engage the rear link
25
of the four-bar linkage, and in particular are received in a pair of hubs 477,
or
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housing defining axle receiving cavities, formed on the connector 479. The
spring
446 has opposite ends 459, 461 screwed onto exterior threads of the T-bushing
458 and the spring bushing 438 respectively, with the spring 446 configured as
an
extensible tension spring that extends in the longitudinal direction 432. It
should
be understood that the rod and spring may be secured to the bushing with other
fasteners, including adhesives, friction fit, set screws, snap fit, detents
and the like.
A tubular shroud 950 surrounds the rod 436 and spring bushing 438 and provides
an aesthetic cover while avoiding pinch points. The shroud 950 is pivotally
connected to the housing 516 with a pair of axles received in tabs, allowing
the
shroud 950 to rotate about an axis 956 defined by the axles 952, which allows
the
shroud to move and rotate with the rod and spring bushing during recline.
[00158] In operation, the recline limiter 430 is rotated at 30 degree
increments about the longitudinal axis 432 defined by the spring bushing 438,
spring 446 and T-rod 436 to present the different stop surfaces 450, 452, 454
to
the ends of the cross member 440 and/or tabs 444 of the spring bushing. In one
embodiment, an actuator component 460 includes a hub portion 472 having a
through opening engaged by a shaft 462 having a lead screw 464 with threads
481. As shown in FIGS. 82A-D and 106A-D, the cross member 440 and tabs 444
do not rotate about an axis, but rather remain stationary as the recline
limiter 430
rotates. As the lead screw 464 is rotated by a handle or knob 466, the rack
(slider)
460 is moved laterally and axially along the lead screw 464 by way of
interfacing/meshing teeth 468, 470 defined by the external threads 481 of the
lead
screw and internal thread 483 of the hub portion 472. The threads may be four
start or eight start. The actuator further includes a linear rack 474
protruding from
the hub portion 472 and secured thereto with an arm 473. The rack 474 is moved
laterally by rotation of the lead screw 464, which may be rotated in either a
clockwise or counterclockwise direction to move the rack side-to-side in a
lateral
direction 4. The rack includes a row of teeth 475 that mesh with teeth defined
by a
circumferential rack 476 disposed around an exterior surface of the spherical
recline limiter 430, with the intermeshing racks 474, 476 rotating the
spherical
bushing 430 about the longitudinal axis 432 within the socket to different
angular
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positions within the ball retainer housing 428. A detent 478 is coupled to an
end
of the lead screw, with the detent having a plurality of surfaces or recesses
engaged by a resilient engagement member 480, formed as the end of a
cantilever
and biased by a spring 491 in one embodiment, which releasably engages one or
more of the surfaces so as to ensure that the lead screw is rotated specific
angular
amounts, corresponding to the 30 degree rotations of the spherical bushing.
The
end 463 of the shaft 462 is rotatably supported by a bushing 482 coupled to
the
housing 428.
[00159] In a full recline/full boost position, shown in FIGS. 82C and
106C,
the tabs 444 of the spring bushing engage a forward stop surface 450 defined
by
the forward face of the spherical bushing, preventing the spring bushing 438
from
moving axially/rearwardly during recline. The cross member 440 of the rod,
however, is free to move in the slot 442 of the spring bushing. Accordingly,
during recline, the rear link 25 engages the T-shaped bushing 458, which pulls
the
rod 436 rearwardly as the cross member 440 moves in the slot 442 of the spring
bushing. Since the spring bushing 438 is immobilized, the spring 446 (which is
fixed to the spring bushing and T-shaped bushing) is stretched or put in
tension,
thereby applying a return force to the rear link 25. When the cross member
encounters the stop surface 454, recline is arrested (full stop).
[00160] In a no-recline stop position, shown in FIGS. 82A and 106A, the
ends of the cross member 440 of the rod 436 engage the forward stop surface
450
defined by the spherical bushing, preventing the rod, attached T-shaped
bushing
and rear link 25 from moving rearwardly.
[00161] In a full recline/no boost position, shown in FIGS. 82D and
106D,
the spring bushing 438 and rod 436 are free to move in the spherical bushing
until
the rod 436 is engaged with the rear stop surface 454 thereof at full recline,
but
with the spring 446 not being extended.
[00162] In a mid-recline/mid-boost position, shown in FIGS. 82B and
106B,
the tabs 444 of the spring bushing 438 engage a forward stop surface 450 of
the
spherical bushing, preventing the spring bushing from moving
axially/rearwardly
during recline. The cross member 440 of the rod, however, is free to move in
the
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slot 442 of the spring bushing to a mid-stop position, wherein the ends engage
an
intermediate stop surface 452 in the spherical bushing spaced longitudinally
rearwardly from the forward stop surface 450 but forwardly of the rear stop
surface 454. Accordingly, during recline, the rear link 25 engages the T-
shaped
bushing 458, which pulls the rod 436 rearwardly as the cross member 440 moves
in the slot 442 of the spring bushing. Since the spring bushing is
immobilized, the
spring (which is fixed to the spring bushing and T-shaped bushing) is
stretched or
put in tension, thereby applying a return force to the rear link 24.
[00163] Importantly, the interface between the socket 424 of the ball
retainer
housing 428 and the outer spherical surface of the recline limiter 430 allows
the
position of the recline limiter 430 to be adjusted to the different stop/boost
positions, but also allows for some play/rotation to accommodate the rotation
of
the rod and other components during recline. For example, the intermeshing
racks
474, 476, and teeth defined thereby, are oriented such that the recline
limiter 430
may rotate about a lateral, horizontal axis. In one embodiment, the recline
limiter,
or spherical bushing, has at least two rotational degrees of freedom,
including for
example rotation of the recline limiter about the longitudinal axis 432 and
also
about the lateral axis, so as to allow the recline limiter to float relative
to the base
and thereby accommodate the flexing of the four bar mechanism about a lateral
axis and any inherent flexing of the seat and back about a longitudinal axis
without
being bound up in the housing 428. The recline limiter may also have a
rotational
degree of freedom allowing rotation about an axis orthogonal to the
longitudinal
and lateral axis, for example an axis extending upwardly, such that the rod
436
may rotate side-to-side to accommodate movement, i.e., bending and twisting,
of
the four bar mechanism during use.
[00164] As noted, the recline limiter assembly interfaces between a body
support member, e.g., seat and/or backrest, and the base to limit the recline
of the
body support member relative to the base. For example, the recline limiter
assembly may interface between the rear link 25 and the base 12, with the rear
link
coupled to both the seat and backrest and controlling the recline of both
components through the rear link 25. In other embodiments, the recline limiter
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may be directly coupled to, or interface directly with, either the seat or
backrest
assemblies 8, 6.
HEIGHT ADJUSTMENT CONTROL:
[00165] The control module may also include an actuator 484 coupled to
the
housing 422 for moving an actuator button 501 extending from a top of support
column 16. The actuator button may be depressed by the actuator 484, thereby
allowing the support column 16 to extend, or to be compressed under load.
Referring to FIGS. 73A-C and 87A and B, the actuator 484 includes a handle 486
rotatably mounted about a lateral axis 488 and having a hollow shaft 490,
through
which the rod 462 and lead screw 468 extends. The end 492 of the shaft 490
engages and rotates a drive gear 494, 1494, with a bushing 833 supporting the
end
in the housing 422. In one embodiment, the drive gear 1494 is configured with
a
radially extending arm 1495 having a plurality of teeth 1496 (shown as four
teeth)
defining a rack 1497. In one embodiment, the rack is a linear rack, with the
teeth
are arranged along a tangent to a curve having a radius defined by the length
of the
arm. In other embodiments, the rack may be a partial, circumferential rack. In
another embodiment, the drive gear may be configured as a segment gear, with a
pair of radii sides and an outer circumferential arc having a plurality of
teeth
positioned around the periphery thereof. The drive gear 494 also has a
plurality of
teeth 496 positioned around a portion of the circumference thereof, and an
adjacent circumferential portion 498 with no teeth, or in other words the
drive gear
494 has an outer surface 499 disposed radially inwardly relative to the
plurality of
teeth 496 so as to define a circumferential recess. The drive gear 494, 1494
is
rotatable about the lateral axis 488 from a non-engaged position to an engaged
position.
[00166] An actuator with a driven gear 500, 1500 is positioned adjacent
the
drive gear and is rotatable about a lateral axis 502 spaced from the lateral
axis
488. A bushing or cover 847 surrounds an axle 841 extending from the driven
gear 1500, which is supported by a pair of lugs 853 formed on the housing 422.
The engagement member rotates about the axle 841 and/or cover 847 between the
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lugs. In one embodiment, the driven gear 1500 is configured as a gear segment,
with a pair of radii sides 1502 and an outer circumferential arc 1504 having a
plurality of teeth 1506 positioned around the periphery thereof. The actuator
includes a tab or lever 504 extending radially from the axle overlying the
actuation
button of the support column. A compression spring 506 biases the drive gear
494
such that the no-teeth portion 498, or surface 499, typically overlies the
driven
gear. The driven gear 500 includes a plurality of teeth 508 disposed around at
least a portion of the circumference of the driven gear, with the recess 498
or
surface 499 overlying the plurality of teeth 508 when the drive gear is in the
non-
engaged position. The drive gear 494 is rotatable to the engaged position such
that
the plurality of teeth 496 are brought into engagement with the plurality of
teeth
508 after a first predetermined amount of rotation of the handle 486 about the
lateral axis 488. The driven gear 500 is thereby rotated from a non-actuated
position to an actuation position about the lateral axis 502 when the drive
gear is
in the engaged position. The user rotates the handle 486 against the biasing
force
of the compression spring 506 until the teeth 496 of the drive gear rotate
into
engagement with the teeth 508 of the driven gear, thereby rotating the
actuator
lever 504 extending from the shaft of the driven gear and actuating the button
517
on the top of the support column 16. An integrated spring 510 is formed in a
carrier bracket to provide a slight-preload to the button. The driven gear 500
is
rotatably supported by a bracket 512 coupled to the top of the housing over
the top
of the support column, with the drive gear and driven gear interfacing in
recess
514 formed in the housing.
[00167] Referring to the embodiment of FIGS. 80, 81 and 87A and B, a
spring 960 has a first end 962 that biases the drive gear 1494 to a disengaged
position such that that the teeth 1496 are disposed below and not engaged or
intermeshed with the teeth 1506 of the driven gear. The spring 960 has an
opposite end 964 that biases the driven gear 1500 and lever 504 toward the
button
517. In this way, the driven gear 1500 may be rotated a sufficient amount such
that the lever 504 is engaged with the button, regardless of the rotation of
the drive
gear, for example to accommodate different support columns having different
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length or size buttons, or wherein tolerance buildup has resulted in a
different
position of the button. In other words, the starting position of the driven
gear may
vary depending on the type and configuration of the support column and button,
prior to engagement by the drive gear, but with the drive gear thereafter
engaging
and rotating the driven gear.
[00168] The drive gear 1494 is rotatable to the engaged position such
that the
plurality of teeth 1496 are brought into engagement and intermeshed with the
plurality of teeth 1506 after a first predetermined amount of rotation of the
handle
486 about the lateral axis 488. The driven gear 1500 is thereby rotated from a
non-actuated position to an actuation position about the lateral axis 502 when
the
drive gear is in the engaged position. The user rotates the handle 486 against
the
biasing force of the spring 960 until the teeth 1496 of the drive gear rotate
into
engagement with the teeth 1506 of the driven gear, thereby rotating the
actuator
lever 504 extending from the shaft of the driven gear and actuating the button
517
on the top of the support column 16.
SEAT ASSEMBLY:
[00169] Referring to FIGS. 1-7C, 8-20 and 84A-D, the seat assembly 8 is
operably coupled to the tilt control assembly 18 and supports a seating
surface 28.
The seat has opposite sides spaced apart in a lateral direction and a front
and rear
spaced apart in a first longitudinal direction. The seat assembly includes a
lower
support platform 30 having a peripheral edge 32, an upper surface 34 and a
lower
surface 36. In one embodiment, the lower support platform has a generally
isosceles trapezoidal shape in plan view (see FIG. 13) with a front edge 38,
rear
edge 40 and side edges 42 joining the front and rear edges. The rear edge is
shorter than the front edge. The peripheral edge 32 may be stepped, meaning a
peripheral edge portion 66 thereof is thinner than a central portion 68
thereof.
[00170] The support platform 30 has a pair of laterally spaced pads 44
positioned at a forward portion of the support platform. As shown in FIGS. 84A-
D, the platform 30 includes a raised portion 970 defining a recess 974 and an
opening 972. The pads are each defined as a hinge portion 976 with a front
edge
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978 secured to a front edge 980 of the platform defining the opening 972 in
the
platform. The hinge portion may be formed by overmolding a more flexible
material to the support platform. The hinge portion 976 extends rearwardly in
the
opening with a rear edge 982 spaced apart from a rear edge 984 of the platform
defining the opening 972. Each of the pads 44 includes at least one mounting
component, shown as openings 46 shaped and dimensioned to receive mounting
members (e.g. fasteners or studs 988) for securing the platform to the tilt
control
assembly, which may include a flange 990 extending forwardly from the link 23
to
support the platforms. The flange 990 is received in the recess 972 and
includes
bosses extending upwardly into the openings 46 such that the flange 990 may be
secured to a bottom surface of the pad, and hinge portion 976 in particular,
with
the plurality of fasteners 988. The flexible hinge portion 976 defines the
flex
region 27 in this embodiment. The mounting component, and connection to the
link 23, allows for pivoting of the support platform and the front link 23
relative to
the base link 33 about a flex region 29, and for pivoting of the seat assembly
8
relative to the front link 23 about flex region 27, executed in both cases for
example by elastic deformation or bending of portions of the front links at
the flex
regions 27, 29, or alternatively by bending or flexing of the pads or hinge
portion
976. At the same time, the spacing W1 between the pads, and front links,
provides
relative stability to the front portion of the seat, which resists rotation or
torsional
movement about a longitudinal axis. A boss structure 49 extends downwardly
from a rear portion of the support platform. The boss structure 49 defines at
least
one mounting component that is connected to the tilt control assembly 18,
and/or
defines a portion of a rear link 25 forming in part the tilt control assembly
and
allows for pivoting of the support platform and the rear link 25 relative to
the base
link 33 about a flex region 31, which may be executed for example by elastic
deformation or bending of portions of the base link 33 at flex region 31. In
one
embodiment, the boss structure 49 has a tubular configuration defining a
cavity
that surrounds or receives an insert portion of the rear link 25, configured
with
features from the connector 479, the 219. The centrally located rear link,
which is
the only support for the rear of the seat, allows for rotation or torsional
movement
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of the rear of the seat relative to the front of the seat about a longitudinal
axis, with
the rotation or torsional movement of the front being restricted as previously
explained. The support platform 30 has a generally concave upper surface 34,
with front and rear portions 35, 37 extending upwardly from the boss
structure.
[00171] The support platform may be made of a flexibly resilient polymer
material such as any thermoplastic, including, for example, nylon, glass-
filled
nylon, polypropy-lene, acetyl, or polycarbonate; any thermal set material,
including, for example, epoxies; or any resin-based composites, including, for
example, carbon fiber or fiberglass, thereby allovving the support platform to
conform and move in response to forces exerted by a user. Other suitable
materials
may be also be utilized, such as metals, including, for example, steel or
titanium;
plywood; or composite material including plastics, resin-based composites,
metals
and/or plywood. The support platform may have strategically positioned tensile
substrates 1220, 1222, made for example of glass reinforced tape, to
accommodate
bending and deformation of the structure, with the tape being put in tension
during
such bending and deformation. Strategic locations on the lower support
platform
also are provided with specific geometries that allow for predetermined
deformations and define "flex regions," otherwise referred to as "flex
joints," or
virtual pivot locations.
[00172] For example, the support platform may include an area of reduced
thickness defining a laterally extending flex region or flexing zone 53
located in
front of the boss structure 49, which divides or bifurcates the support
platform into
front and rear portions, which may have different lengths or dimensions, with
the
rear portion being downwar&t,' deflectable relative to the front portii-in
during
recline as the flex region bends. The portion of the support platform
extending
between the flex region 53 and the flex region 27 defines a link of a four bar
mechanism, while a portion of the support platform rearward of the flex region
53
defines in part a portion of the rear link 25. It is noted that the relative
areas of
reduced thickness may extend along a short distance or the majority of the
width
of the support platform depending upon the support and bending characteristics
desired. The phrase "flex region" refers to a portion of the structure that
allows
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for flexing or bending in the designated region, thereby allowing or providing
for
relative movement (e.g., pivoting) of the component or structure on opposite
sides
of the flex region, thereby defining a virtual pivot location, for example a
horizontal pivot axis, with the understanding that the virtual pivot axis may
move
during the flexing, rather than being defined as a hard fixed axis. The
various
configurations and materials of the support platform may correspond to the
configuration and materials of various components as shown and disclosed in
U.S.
Pub. No. 2016/0296026 Al, entitled "Seating Arrangement," and in U.S. Pub. No.
2018/0352961, entitled "Seating Arrangement and Method of Construction," the
entire disclosures of which are hereby incorporated herein by reference.
[00173] A support ring 48 has an inner ring 50 with an interior
peripheral
edge 52 that defines a central opening 54. The interior peripheral edge 52
surrounds and is coupled to the outer peripheral edge 32 of the support
platform,
namely the rear edge 40, front edge 38 and side edges 42, of the support
platform
30, which is received in the opening 54. The inner ring 50 has a trapezoidal
shape
defined by a front member 56, a rear member 58 and a pair of side members 60
defining the opening 54. The interior peripheral edge 52 may be stepped,
meaning
a peripheral edge portion 70 thereof is thinner than a central portion 72
thereof,
with the edge portion 70 overlapping and mating with the edge portion 66 of
the
lower support platform. As shown in FIG. 7A, the edge portion 70 is positioned
above the edge portion 66, with an upper surface of the peripheral edge 52
lying
flush with the upper surface of the support platform 30. The edge portions 70,
66
may be secured with fasteners, such as screws and/or adhesive. It should be
understood that the support platform 30 and support ring 48 in combination
define
a support frame 62.
[00174] In one embodiment, the support ring 48 further includes an outer
ring
74 with side members 76 joined to side members 60 of the inner ring with a
pair of
front connectors 78 and a pair of intermediate connectors 80. A pair of rear
three-
sided openings 81 are defined between an inner edge of the outer ring 74, an
edge
of the side member and the edges of the connectors 80. The openings 81 each
have an inner side 85, a longer, outer curved side 87, with the sides 87 and
85
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converging along the rear of the opening 81 to define a nose 89, and a third
side 91
extending along and defining the connector 80 and joining the sides 85, 87. A
pair
of front three-sided openings 83 are defined between an inner edge of the
outer
ring 74, an edge of the side member 60 and the edges of the connectors 80. The
openings 83 each have an inner side 93, a longer, outer curved side 95, with
the
sides 93, 95 converging along the front of the opening 83 to define a nose 99,
and
a third side 97 extending along and defining the connector 80 and joining the
sides
93, 95.
[00175] It should be understood that in one embodiment, the intermediate
connectors 80 may be omitted. The outer ring has a front cross member 82 and a
rear member 58, which it shares with the inner ring, and which are connected
to
the side members 76. The front cross member 82 is spaced apart from the front
member 56, which define an elongated and laterally extending U-shaped opening
84 therebetween. A flexible membrane 55 covers the opening 84, is connected to
the support ring around the perimeter of the opening, and maintains the
spacing
between the cross member 82 and front member 56 when the cross member 82
flexes relative to the front member 56, for example when undergoing a load
applied by a user's thighs. The membrane 55 may also serve as a limiter by
limiting the amount of deflection of the cross member 82 when the load is
applied
thereto. The membrane 55 may be made of urethane, and may be over molded on
the support ring 48 to cover the opening 84. Side slots 86 allow for front
portions
88 of the side members 76 to flex or bend such that the front member 82 may
deflect when loaded by the user's legs, while the connectors 78, 80 provide
greater
rigidity to the outer ring 74. An outer peripheral edge 90 is stepped, meaning
a
peripheral edge portion 92 thereof is thinner than the central portion 72
thereof. A
pair of lugs 94 extend downwardly from the inner ring and are disposed along
the
sides of the boss structure, where they are supported by the tilt control
assembly
18. The support ring 48 extends radially outwardly from the lower support
platform 30. The support ring, including the outer ring, the inner ring and
connectors, defines an upper surface 96 and a concave cavity 98. The support
ring
48 is made of a compliant flexible material, which is configured to position
and
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hold the flexible edge member 162, described in more detail below. The support
ring 48 is less stiff than the support platform, and has a modulus of
elasticity that
is less than a modulus of elasticity of the support platform. The support ring
may
be made, for example, of polyester urethane, or a thermoplastic polyester
elastomer.
[00176] An upper shell, also referred to as a carrier frame 100, has a
central
portion 102 overlying the inner ring 52 of the support ring and the lower
support
platform 30, and an outer ring 104 overlying the outer ring 74 of the support
ring
and the upper surface 34 of the support platform. The outer ring 104 and
central
portion 102 of the upper shell are coupled with at least two connectors,
including a
pair of front connectors 106 and a pair of intermediate connectors 108, which
are
curved with an upwardly facing concave curvature such that is rigid and
resists
outward/downward deflection/deformation.
[00177] A pair of rear three-sided openings 109 are defined between an
inner
edge of the outer ring 104, an edge of the central portion 102 and the edges
of the
connectors 108. The openings 109 each have an inner side 111, a longer, outer
curved side 113, with the sides 111, 113 converging along the rear of the
opening
109 to define a nose 115, and a third side 117 extending along and defining
the
connector 108 and joining the sides 111, 113. A pair of front three-sided
openings
119 are defined between an inner edge of the outer ring 104, an edge of the
central
portion 102 and the edges of the connectors 108. The openings 119 each have an
inner side 121, a longer, outer curved side 123, with the sides 121, 123
converging
along the front of the opening 119 to define a nose 125, and a third side 127
extending along and defining the connector 108 and joining the sides 121, 123.
[00178] The outer ring 104 has a front cross member 110 and a rear
member
112 that are connected to side members 114. The outer ring has a peripheral
length defined around the perimeter thereof, with the length being fixed or
maintained as a relative constant during recline of the seat. In other words,
in one
embodiment, the outer ring 104, defined by the side members 114, front cross
member 110 and rear member 112, does not elongate during recline, or does not
undergo elastic deformation along a tangent or length thereof in response to
tensile
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forces, although the outer ring 104 is capable of bending or flexing as
described in
more detail below. The front cross member 110 is spaced apart from a front
edge
116 of the central portion 102, which define an elongated and laterally
extending
U-shaped opening 118 therebetween. Side slots 120 allow for front portions 122
of the side members 114 to flex or bend such that the front cross member 110
may
deflect when loaded by the user's legs, while the connectors 106, 108 provide
greater rigidity to the outer ring 104. The connectors 106, 108 overlie the
connectors 78, 80, with openings 84 and 118, along with membrane 53, being
aligned. The upper shell includes pads 124 that overlie the pads 46. The upper
shell 100 is secured to the support platform with fasteners, including for
example
hooks and screws.
[00179] The upper shell, or carrier frame 100, is flexible, but stiffer
than the
support ring 48, and has a modulus of elasticity that is greater than the
modulus of
elasticity of the support ring, but the carrier frame is less stiff than, and
has a
modulus of elasticity less than a modulus of elasticity of the support
platform 30.
The upper shell, or carrier frame 100, may be made of a flexibly resilient
polymer
material such as any therinopl:astic, including, for example, nylon, glass-
filled
nylon, polypropylene, acetyl, or polycarboriate, any thermal set material,
including, for example; epoxies; or any resin-based composites, including, for
example, carbon fiber or fiberglass, thereby allowing the support platform to
conform and move in response to forces exerted by a user. Other suitable
materials
may be also be utilized, such as metals, including, for example, steel or
titanium;
plywood; or composite material including plastics, resin-based composites,
metals
and/or plywood.
[00180] The intermediate connectors 108 of the upper shell 100 may
include
an area of reduced thickness defining Ilex regions or flexing zones 155. The
upper
shell 100 also may have an area of reduced thickness defining a flex region or
flexing zone 153 that o-verlies the flex region 53 of the underlying support
platform, located in front of the boss structure 48.
[00181] The upper shell, or carrier frame 100, has a body facing upper
surface 126, a lower surface 128 opposite the upper surface 126 and a
peripheral
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edge surface 130, or side edge face, extending between the first and second
surfaces 126, 128. In one embodiment, the peripheral edge surface 130 is
substantially planar and has a vertical orientation, although it should be
understood
that the edge surface may be curved, curvilinear, or non-planar, and/or may be
oriented at angles other than a vertical plane. The carrier frame 100 defines
a
concave cavity 132 with the outer ring defining a central opening 134.
[00182] A peripheral groove 136 is formed in and opens outwardly from
the
peripheral edge surface 130 or face. The groove 136 extends around at least a
portion of the carrier frame, and in one embodiment, extends continuously
around
the entire periphery of the carrier frame 100. The peripheral edge portion 92
of
the support frame 62 extends outwardly beyond the face 130 of the carrier
frame
as shown in FIGS. 7A-C. The peripheral groove 136 defines an insertion plane
137 oriented at an angle a relative to the peripheral edge surface 130, and
relative
to a gap G adjacent thereto. In various embodiments, a is greater than 0
degrees
and less than 180 degrees, and is preferably between 30 and 120 degrees, and
more preferably between 45 and 90 degrees. Defined another way, the insertion
plane 137 is preferably oriented relative to a landing portion 144, or tangent
of a
textile material 150 supported thereby, such that the insertion plane is
parallel to
the landing portion and tangent, or forms an angle B that is preferably
between 135
and 180 degrees. The peripheral groove 136 has a pair of spaced apart
surfaces,
e.g., upper and lower surfaces 138, 140, and a bottom 142 connecting the
surfaces
138, 140. The upper surface 126 of the upper shell has a landing portion 144,
which is substantially horizontal, and an angled portion 146 that extends away
from the landing portion and defines the cavity. The landing portion 144 may
have a width (W) approaching 0, with the landing portion defined simply by an
upper corner of the edge surface 130. In one embodiment, shown in FIG. 92, a
lip
portion 139 running along the front of the carrier frame defines in part the
groove
136. The lip portion 139 has a plurality of tabs 141 separated by notches 143,
which increase the flexibility of the carrier frame, but provide sufficient
rigidity to
retain the stay.
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[00183] A
textile material 150 is secured to the carrier frame 100 across the
central opening 134 such that it covers the concave cavity 132. The textile
material may be a suspension material, or may cover a cushion supported by the
support and/or carrier frames 64, 100. The textile material covers the upper
surface 126 of the upper shell, and engages the landing portion 144. The
textile
material 150 wraps around and engages a portion of the outer peripheral edge
surface 130, and in particular an upper portion 152 of the peripheral edge
surface
extending between the groove 136 and the upper surface 126, or landing portion
144 thereof. A peripheral edge portion 154 of the textile material 150 is
coupled
to the peripheral edge of the upper shell, for example with the edge portion
154 of
the textile material being disposed in the groove 136. In one embodiment, a
stay
156 (shown in FIG. 20 without the textile material), formed for example by a
ring
(e.g., a plastic or polyester), may be secured to the edge portion of the
textile
material, for example with adhesives, sewing/stitching, fasteners and other
devices, or by forming a loop disposed around the stay. In one embodiment, the
stay has one surface 158 facing and engaged with the textile material and an
opposite surface 160 that remains uncovered. The stay 156 and edge portion 154
of the textile material, which is configured as a suspension material, are
disposed
in the groove 136 to secure the suspension material in tension across the
opening.
In one embodiment, the stay 156 is formed as a continuous ring having a fixed
length, with the stay 156 being relatively inelastic and resistant to
elongation along
a length thereof, but which may be flexible and bendable so as to move with
the
side members 114 and outer ring 104 during recline of the seat. In one
embodiment, as shown in FIGS. 7A-7C, the exposed or uncovered surface 160 of
the stay 156 directly engages the surface 138 of the groove, without any
textile
material or other substrate disposed therebetween. The angular orientation of
the
groove 136 and stay 156 relative to the edge surface helps to ensure that the
stay
156 does not become dislodged from the groove. In one embodiment, the stay 156
and textile material 150 are inserted into the groove 136 without any
auxiliary
fastening systems, such as adhesive or mechanical fasteners, but rather are
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engaged only by friction as the textile/suspension material is put in tension
as
explained hereinafter.
[00184] In another embodiment, and referring to FIGS. 44 and 45, the
support frame 62 includes a bottom wall 518 defining a body facing surface and
a
peripheral edge wall 520 having an outer surface 522. A lip 524, or catch,
defined
in one embodiment by a tab, extends laterally inwardly from the peripheral
edge
wall 520 and defines a channel 526 with the bottom wall. Along a side portion
of
the seat, shown in FIG. 45, the lip or catch has an engagement surface 528
that
angles upwardly and inwardly from the peripheral edge wall while an upper
surface of the wall is substantially horizontal. Along a front portion of the
seat,
shown in FIG. 44, the upper surface of the lip is angled downwardly and
inwardly,
while the engagement surface 528 is substantially horizontal.
[00185] A carrier frame 100 has a body portion 530 with a bottom surface
532 overlying and engaging the bottom wall and an insert portion 534 that is
received in the channel 526 and engages the engagement surface 528. As shown
in FIG. 44, the carrier frame has an upper surface 536 that is angled
downwardly
and inwardly, matching the top surface of the lip or catch, such that
suspension
material may deform against the angled surface. As shown in FIG. 45, the
insert
portion 534 is angled downwardly and outwardly so as to mate with the
engagement surface. The orientation of the insert portion 534 facilitates
installation as the insert portion may be more easily inserted into the
channel when
oriented at an angle such that the insert portion is underlying the lip 524.
Tension
applied by the textile material 150, configured as a suspension material in
one
embodiment, thereafter applies a moment to the carrier frame causing it to
bear up
against the bottom surface of the support frame and the engagement surface
528.
A flexible edge member 162 is coupled to the outer surface 522 of the
peripheral
edge wall of the support frame, with a lip portion 538 overlying a top surface
of
the support frame. The flexible edge member 162 has an inner surface spaced
apart from and facing inwardly toward the peripheral edge wall of the carrier
frame, with the inner surface and the peripheral edge wall of the carrier
frame
defining a gap therebetween. A portion of the textile material is disposed in
the
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gap, with the textile material covering the body facing surface of the carrier
frame.
The carrier frame has a peripheral edge 540 facing outwardly, and includes a
groove 542 opening laterally outwardly therefrom. The peripheral edge of the
textile material is secured to a stay 156, with the edge portion of the
textile
material and the stay disposed in the groove 542.
SUSPENSION MATERIAL:
[00186] In one embodiment, the textile material is made of an
elastomeric
woven or knitted material, and may be configured as a suspension material
having
heat-shrinkable yarns and heat shrinkable elastomeric monofilaments, which
shrink in response to the application of energy, for example heat, whether
applied
by radiation or convection. Various suitable suspension materials are
disclosed in
U.S. Patent No. 7,851,390, entitled "Two-Dimensional Textile Material,
Especially Textile Fabric, Having Shrink Properties and Products Manufacture
Therefrom," the entire disclosure of which is hereby incorporated herein by
reference. One commercially suitable heat-shrink suspension material is a
SHRINX fabric available from Krall + Roth, Germany.
[00187] Referring to FIG. 56, in one embodiment, the suspension material
is
made from a fabric blank 500 having a plurality of heat shrinkable, elastic
(elastomeric) threads 552, configured as monofilaments in one embodiment,
running in a first, lateral direction 4, or warp direction, and a plurality of
non-
extensible threads 554, configured as yarns or monofilaments in various
embodiments, running in the same lateral/warp direction 4. It should be
understood that the heat shrinkable, elastic threads (e.g., monofilaments) and
non-
extensible threads (e.g., monofilaments) may also run in the longitudinal
direction
2, 2'. In one embodiment, the heat shrinkable, elastic threads 552 and the
plurality
of non-extensible threads 554 alternate 1:1 or 2:1, or are disposed side-by-
side as
shown in FIG. 56, with various embodiments having a weave density of 4-10
elastic threads/cm, more preferably 7-9 elastic threads/cm, and a weave
density of
8 elastic threads/cm in one embodiment. In other embodiments, the ratio of
threads may be altered, with more or less elastomeric threads than non-
extensible
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threads. In one embodiment, the elastic threads are about 0.40 mm in diameter,
with the understanding that the elastic threads may be made thicker or thinner
depending on the desired spring rate. It should be understood that more or
less
elastic threads may be used depending on the cross-sectional area of the
thread.
For example, the weave density may be defined by a total cross-sectional area
of
the combined elastic thread(s) per cm (measured longitudinally), including for
example elastic thread(s) having a combined cross-sectional area (whether a
single
thread or a plurality of threads) between 0.502 mm2/cm and 1.256 mm2/cm in
various embodiments, more preferably between 0.879 mm2/cm and 1.130
mm2/cm, and a combined cross-sectional area of 1.005 mm2/cm in one
embodiment.
[00188] A
plurality of yarn strands 556 are interwoven with the elastomeric
and non-extensible threads 552, 554 in the weft direction, or longitudinal
direction
2, 2' in one embodiment. The non-extensible threads 554 and the yarn strands
556
do not shrink when exposed to heat or energy, and are not elastomeric. Rather,
the
yarn strands 556 provide shape control to the overall suspension material in a
final
configuration after heat shrinking. The yarn strands 556 may be made of
various
colors, e.g., blue, to provide color to the textile material. The overall
color of the
blank is thereby easily changed simply by introducing different yarns in the
weft
direction. In contrast, the elastomeric threads are preferably transparent or
black.
[00189]
Referring to FIGS. 55 and 85, an annular stay 156 is secured to the
fabric blank for example by sewing or with staples or other fastening systems,
with the annular stay having first and second annular edges 558, 560. The
annular
stay is rotatable 180 degrees between a first configuration, wherein the first
annular edge 558 is disposed radially inwardly from the second annular edge
560,
and a second configuration, wherein the first annular edge 558 is disposed
radially
outwardly from the second annular edge 560 as shown in FIGS. 44 and 45. The
first annular edge 558 on opposite sides of the stay define first and second
dimensions therebetween in the first lateral direction 2, 2' when the stay is
in the
first and second configurations, wherein the first and second dimensions are
substantially the same in one embodiment, meaning as the stay is rotated, the
first
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annular edge remains stationary, albeit rotated 180 degrees. The stay 156
includes
open notches 157 in the second annular edge, which close and allow for the
stay to
be rotated from the first to second configurations. The fabric blank 500 is
initially
configured with pockets of extra material at the corners to accommodate the
rotation of the stays at those corners. After rotation, the stay 156 may be
installed
in the carrier frame 100, with the carrier frame and fabric then installed or
coupled
to the support frame 62, with the flexible edge 162 connected to the support
frame
62 and disposed around the periphery of the textile material.
[00190] Energy, such as heat, may be applied to the fabric blank from an
energy source, causing the heat shrinkable elastomeric threads 552 to shrink.
In
other embodiments, the textile material is wrapped around or covers a cushion
or
underlying substrate such as a plastic or metal web, which supports the user,
with
the edge of the textile material secured to the carrier frame as described
herein. In
those embodiments, the textile material 150 may be, but is not necessarily,
put in
tension around the cushion or across the opening 134.
[00191] The flexible edge member 162 is configured as a ring surrounding
and coupled to the peripheral edge 92 of the support frame. It should be
understood that the ring may be continuous, or that the flexible edge member
may
extend only partially around the periphery of the carrier frame 100. The
flexible
edge member 162 extends upwardly from the support frame 64 and has an inner
peripheral surface 164, or face, facing inwardly toward, and spaced apart
from, the
peripheral edge surface 130 of the carrier frame so as to form a gap G, for
example
and without limitation having a width of between 0.50 to 1.00 mm that is
communication with the groove 136, meaning the groove and gap form a
continuous, but non-linear slotted opening or pathway that receives the
textile
material 150. In one embodiment, the inner surface 164 is substantially planar
and
has a vertical orientation and extends in the Z direction, although it should
be
understood that the edge surface may be curved, curvilinear, or non-planar,
and/or
may be oriented at angles other than a vertical plane. In one embodiment, the
inner surface 164 has substantially the same shape as the peripheral edge
surface
130 such that the gap G is maintained constant, regardless of whether either
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surface or the gap G is linear. In one embodiment, the gap G is the same or
slightly larger than the thickness of the textile material, which may have a
thickness of about 0.75 to 1.00 mm, while in other embodiments, there is no
gap
(i.e. G=0), or the gap G is less than the thickness of the textile material,
with the
surfaces 130, 164 abutting, and/or squeezing or slightly compressing the
textile
material 150 therebetween. The inner surface 164 faces and covers the groove
136
and textile material 150. In addition, the flexible edge member 162 further
entraps
the stay 156 and textile material 150, thereby further helping to ensure that
the
stay 156 does not become dislodged from the groove 136.
[00192] The
flexible edge member 162 is made of a thermoplastic olefin or
thermoplastic elastomer, and may be made of the same material as the membrane
53, such that the flexible edge member may be compressed, for example if
impacted. The flexible edge member 162 has a greater resilience, or is more
flexible and has a substantially lower modulus of elasticity less than the
support
frame 62, with a durometer in the shore D range, with one embodiment having a
durometer of 80-90. The flexible edge member 162 protects the textile material
150 from inadvertent impact and wear and has an upper surface 166
substantially
flush with, or slightly lower than, an upper surface 168 of the textile
material 150,
thereby preventing snags and providing a pleasing appearance. As mentioned,
the
flexible edge member 162 abuts, or is slightly spaced from, the portion of the
textile material 150 disposed between the flexible edge member 162 and carrier
frame 100. The flexible edge member has a groove 170, with the peripheral edge
92 of the support ring being disposed in the groove 170. In one embodiment,
the
flexible edge member 162 is over molded onto the peripheral edge 92 of the
support frame 62, or support ring, and may be made of the same material as the
membrane 53. In other embodiments, the flexible edge member may be secured to
the support frame by friction, or with adhesives, mechanical fasteners, such
as
staples or screws, or combinations thereof. The geometry of the flexible edge
member 162 further promotes the protective and elastic properties thereof. For
example, the flexible edge member 162 may be tapered from a first thickness Ti
along the inner surface 164 to a second thickness T2 at an outermost
peripheral
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edge thereof, with the thickness being measured parallel to the inner surface
164,
or in substantially the Z direction. In one embodiment, the nose tapers to a
point
where T2=0. In one embodiment, the flexible edge member 162 in cross-section
has a rounded nose shape. The flexible edge member 162 may be compressed in
response to a load applied in the X and/or Y directions, or may deflect in
response
to a load applied in the Z direction as shown in FIG. 7B.
[00193] In one embodiment, an auxiliary support member 200, shown as a
cushion, is disposed between the upper surface 126 of the carrier frame 100
and a
bottom surface 190 of the textile material 150, configured as a suspension
material, or the space defined therebetween. An upper surface 202 of the
auxiliary
support member 200 is spaced apart from the bottom surface 190 of the
suspension material such that a gap G2 or space is defined therebetween when
the
suspension material is in an unloaded configuration (i.e., without a user
disposed
on the suspension material). In various embodiments, the gap G2 may be
maintained as a constant, with the cushion having a contoured upper surface
202
that matches the contour of the bottom surface 190 of the suspension material.
In
various embodiments, the gap G2 is greater than 0 and less than 5 mm, and in
one
embodiment is 3 mm, such that the suspension material contacts the auxiliary
support member 200 as soon as the user engages, or sits on, the suspension
material. The auxiliary support member 200 may have a generally trapezoidal
shape in plan view that matches the shape of the central portion 102 of the
carrier
frame or the support platform 30. The auxiliary support member 200 extends
forwardly to cover the opening 118 and support the thighs of the user. The
auxiliary support member may be made of foam. The auxiliary support member
200 may be secured to the support platform 30 and/or carrier frame 100 with
fasteners, including mechanical fasteners such as screws or adhesive. In one
embodiment, the auxiliary support member 200 has a bottom substrate 201, for
example a plastic or wood sheet, that may be engaged with fasteners and which
is
connected to, or embedded in, an upper foam cushion 203 as shown in FIG. 20.
[00194] In operation, and referring to FIGS. 18, 19 and 21, as a user
sits on
the suspension material 150, the load applied to the suspension material 150
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causes it to deflect downwardly toward the auxiliary support member 200. If
the
load is such that the suspension material deflects across the distance G2 and
comes
into contact with the auxiliary support member 200, the auxiliary support
member
200 thereafter may absorb the additional loading and support the user.
[00195] It should be understood that in other embodiments, the auxiliary
support member 200 abuts and supports the textile material in an unloaded
condition. For example, the textile material may simply cover a cushion, which
fills the space of the cavity 132 of the carrier frame, with the textile
material
forming an upholstery cover over the top of the cushion.
[00196] In one embodiment, a method of manufacturing or assembling a
body support member 10 includes positioning and securing the auxiliary support
member 200 on top of the carrier frame 100. The method further includes
disposing the peripheral edge portion 154, 252 of the textile material 150,
234 into
the peripheral groove 136, 244 formed in the peripheral edge surface 130, 246
of
the frame, with the stay 156, 250 engaging one surface of the groove. As the
stay
156, 250 is rolled over for insertion into the groove, the suspension material
covers the portion of the peripheral edge surface 130, 246 between the groove
and
the upper (or front) surface 126 (i.e., body-facing first surface of the
frame). The
carrier frame 100, 242 is then connected to the support frame 62, 236, which
has a
flexible edge member 162, 240 secured thereto for example by way of support
ring
48. Conversely, the flexible edge member 162 may first be connected to the
carrier frame 100, for example by way of the support ring 48, with those
components thereafter being coupled to the support platform 30. In one
embodiment, the flexible edge member 162, 240 is secured to the support frame
62, or support ring 48, by over molding the flexible edge member 162 onto the
peripheral edge 92 of the support frame/support ring. The flexible edge member
may be secured in other ways, including with adhesive or mechanical fasteners.
Energy, for example thermal energy or heat applied by radiation or convection,
may be applied to the suspension material 150, 234, causing the suspension
material to shrink and create tension therein. The energy may be applied to
the
suspension material either before or after the carrier frame 100, 242 is
secured to
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the support frame 62, 212. As the suspension material shrinks, the suspension
material is put in tension across the opening 134 and the stays 250, 156 are
anchored in the grooves 136, 244.
BACKREST ASSEMBLY:
[00197] Referring to FIGS. 1-6, 7B, 22-43 and 77-79, the backrest
assembly
6 includes a back frame 210 and a back support 212, otherwise referred to as a
support frame. The back frame is relative rigid, meaning it does not
substantially
flex/bend or otherwise elastically deform during recline. The back frame 210
has
a lower portion 214 that is connected to the rear portion of the tilt control
assembly 18. The portion 214 includes an upwardly extending arm 992 or post
structure having a forwardly facing cavity 994 in which the arm 407 is
disposed or
nested. The connector 479 has a downwardly facing cavity 938 in which the arms
407, 992 are disposed or inserted, thereby trapping and securing the arms 407,
992
to together to define at least in part the rear link 25. A front wall 944 of
the
connector, defining in part the cavity 938, has a forwardly curved lip that
transitions towards and interfaces with the lower portion 400, while a rear
wall
946 nests in a recess defined by a rear of the arm 992. The lower portion 214,
or
lower support arm, extends generally horizontally in the longitudinal
direction 2'
along a central axis of the seating structure. The lugs 94 of the seat
assembly
extend downwardly from the inner ring and are disposed along the sides of the
boss structure 49, where they are disposed in the cavity or otherwise secured
to the
arm and rear link. The boss structure 49 covers the top of the cavity and
captures
the cross member 471 therebetween as shown in FIG. 79, with an upper portion
940 of the connector 479 defining an insert portion received in the boss
structure
49. The boss structure 49 and connector 479 define a forwardly facing opening
942 through which an end of the shroud 950 is disposed as shown in FIG. 78.
The
back frame 210 is pivotable with the rear link 25 about the flex region 31,
with the
lower portion 214 being an extension of and defining in part the rear link 25.
The
back frame 210 is pivotable rearwardly relative to the base 12 during recline.
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[00198] A transition portion 216, which is a curved and defines a
rearwardly
facing convex bow shape in one embodiment, extends rearwardly and upwardly
from the lower portion 214. A pair of laterally spaced uprights 218 extend
upwardly from the transition portion 216. The back frame 210 further includes
an
upper cross member 220 extending between and connecting upper ends of the
uprights 218, with the cross member 220, upright 218 and lower portion 214
defining a central opening. The lower portion, including a portion (arm 992)
of
the rear link, uprights, and cross member may be integrally formed. As shown
in
FIG. 49, the cross-section of the uprights 218 are angled forwardly and
outwardly,
which increases the (bending) moment of inertia of the uprights and thereby
makes
the uprights, in combination, resistant to flexing or bending about a lateral
axis 4,
and also resistant to deformation in the lateral direction, i.e., resistant to
bending
about the horizontal longitudinal axis 2'. It should be understood that in an
alternative embodiment, the back frame may include a single upright, for
example
a central spine member arranged along a longitudinal centerline of the
backrest,
with laterally extending arms having ends connected to the back support.
Alternatively, the upright may be configured as a shell that extends laterally
between and has side portions connected to the back support. The back frame
may
also be configured with more than two uprights.
[00199] The back support 212, otherwise referred to as a support frame,
is
flexible, and includes flex regions 225, 233 allowing it to bend and deflect
in
response to the user reclining in the body support structure. The back support
has opposite sides spaced apart in the lateral direction and a top and bottom
spaced
apart in a longitudinal direction. The back support, or support frame 212,
includes
a pair of laterally spaced uprights 222, each having a forwardly facing convex
bow
shaped portion 223 at a first location proximate a lumbar region of the back
support, with each bow shaped portion including and defining a flex region
225,
which may be configured with thinner and flatter cross-sections, or sections
having lower bending moments of inertia, for example about a horizontal axis,
than the adjacent or remaining portions of the uprights. It should be
understood
that in an alternative embodiment, the back support may include a single
upright,
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for example a shell that extends laterally between and has side portions
connected
to the back frame. The shell may be made of a flexible plastic. The shell may
have a flex region defined laterally across the entire width thereof adjacent
the
lumbar region. The shell may have a forwardly facing concave contour, with
side
portions positioned forwardly of a central portion and defining a lateral
space
therebetween, and may support a suspension material secured to the side
portions
across the lateral space, for example with stays as disclosed herein. If
configured
with a single upright, the back support may be connected to the back frame,
whether configured with one more uprights, with a pair of connectors arranged
along each side of the single upright.
[00200] A bottom portion 224 extends between and connects the uprights.
The back support 212 further includes a lower portion or support arm 226 that
extends forwardly from the bottom portion, with the support arm or lower
portion
coupled to the control assembly, and in particular the rear link 25 below the
seat
support member 6. The lower portion includes a transition portion 217
connecting
the support arm 226 and the bottom portion 224. The transition portion 217 has
a
rearwardly facing convex bow shape, with the curved transition portion 217
also
having a forwardly facing concave bowl shape, with the curvature of the
transition
portion making it relative rigid, or resistant to flexing or bending. The
front end of
the lower portion 226 has an upturned central lip 219 or post and a pair of
laterally
spaced lugs 221, which partially surround upwardly extending boss structures
998
on the connector 479, with the lip 219 and lugs 221 connected to and defining
part
of the rear link 25, with the seat platform, seat support, back frame and back
support all having overlapping portions defining in part the rear link. The
lip 219
is captured by a rear wall 331 of the boss structure 49. A relatively thin and
flat
section 231 of the lower portion extending in a longitudinal direction 2'
defines a
flex region 233 below the seat support and seating surface, and between the
rear
link 25 and the lumbar region 223 of the backrest and the flex region 225
defined
thereby, which permits the transition portion 217 to pivot relative to the
rear link
25 about the flex region 233. The thinner and flatter cross-section has a
lower
bending moment of inertia about a horizontal axis than the adjacent or
remaining
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portions of the lower portion. In one embodiment, one or both of the flex
regions
225 and 233 may be formed as a living hinge, or a thin flexible hinge made
from
the same material as the two more rigid pieces the living hinge connects, so
as
provide for relative rotation or pivoting between the more rigid pieces by
bending
of the living hinge.
[00201] Flex regions 225 are defined in each of the uprights 222
adjacent the
lumbar region above the seating surface, with the lumbar regions of the
uprights
having a forwardly facing convex curvature. The back support has an S-shaped
profile when viewed from a right side thereof as shown in FIGS. 25, 37 and 39.
The uprights 222 of the back support are coupled to the uprights 218 of the
back
frame with connectors 228. The uprights 222 are disposed laterally outwardly
and
forwardly of the uprights 218, with a lateral space defined therebetween. The
back support 212 is pivotable with the back frame 210 and rear link about the
flex
region 31. In one embodiment, the uprights 218, 222 may be pivotally connected
with a mechanical pivot joint, including for example the pivot structure
disclosed
in U.S. Patent No. 9,826,839, the entire disclosure of which is hereby
incorporated
herein by reference.
[00202] In another embodiment, each of the pair of connectors 228
extends
laterally between one of the back frame uprights 218 and one of the back
support
uprights 222. The connectors include a first connector tab 570 extending
laterally
from the back frame upright and a second connector tab 572 extending laterally
from the back support upright, with the first and second connector tabs 570,
572
overlapping. The connector tab 572 is disposed rearwardly of covers the
connector tab 570. The connector tab 572 is relatively rigid and not flexible
such
that the back support 212 is not moveable in a fore/aft direction relative to
the
back frame at the location of the connectors 228. The first connector tab 570
has a
first insert portion 574 received in a channel 576, or socket, formed in the
back
support upright, while the second connector tab 572 has a second insert
portion
578 received in a channel 580, or socket, formed in the back frame upright.
The
first and second connector tabs 570, 572 are coupled with a vertically
extending
pin 582 at a location between the first and second uprights, which location is
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proximate a neutral pivot axis extending in a lateral direction. The first
connector
tab 570 has a through opening, or horizontally elongated slot 584, at the mid-
point,
and a pair of lugs 586 extending forwardly from a front surface of the tab
adjacent
a top and bottom of the slot 584, with the lugs defining axially aligned
through
openings 590. The second connector tab 572 includes a forwardly facing lug 588
extending from a front surface, with the lug 588 inserted through the slot 584
and
having a through opening aligned with the openings 590 of the lugs. The pin
582
is inserted upwardly through the openings of the lugs on the front side of the
connector tabs so as to secure the tabs 572, 574 one to the other. The pin 582
may
have a head and be threadably engaged with one or all of the lugs 588, 586,
and
preferably at least the uppermost lug 586. The suspension material 150 is
disposed over and covers the front of the tabs, the pins and the lugs.
[00203] The insert portions 574, 578, which are non-cylindrical, are
rotatable
about a laterally extending axis 592 relative to the channels or sockets 576,
580 as
the back support flexes about flex regions 225, 233 relative to the back frame
210
and rear link 25. The connector tabs each include a shoulder portion 594 that
abuts a stop surface 596 of the opposing upright so as to locate the connector
tabs
and align the lugs.
[00204] Referring to FIGS. 52 and 74-76, the insert portion 574 of the
first
connector tab 570 has opposing front and rear convex curved engagement
surfaces
598, 600 that interface with opposing stop surfaces 599, 601 of the channel or
socket 576 having a substantially rectangular cross sections. As such, the
upright
222 and channel 576 may rotate or pivot relative to the insert portion 574
about an
axis 603 in first and second rotational directions until the engagement
surfaces
598, 600 on opposite ends 602 of the insert portion engage opposite stop
surfaces
599, 601 defined by the walls of the channel or socket at opposite ends
thereof and
thereby limit the pivoting motion in either rotational direction. As shown in
FIG.
50, the rear surface of the connector tab 570 also has a rearwardly facing
curved
surface 604 that interfaces with a flat surface 606 of the overlapping
connector tab
570, so as to not inhibit rotation of the upright 222, and connector tab 572,
relative
to the first connector tab 570, which is relative rigid and immobile.
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[00205] Referring to FIG. 74, the insert portion 578 of the second
connector
tab 572 also is configured with convex curved surfaces 608, which allows for
pivoting of the connector tab 572 relative to the channel 580 and upright 218.
In
this way, the back support uprights 222 pivot or rotate relative to the back
frame
uprights 218 about axes 592 between various pivot positions, including at
least
first and second pivot positions, wherein the insert portion 574 engages first
and
second stop surfaces of the first channel 576, and the insert portion 578
engages
first and second stop surfaces of the channel 580. For example and without
limitation, the uprights 222 may be rotated 5 and 7 degrees relative to the
uprights
218.
[00206] The spacing W2, for example about 330mm in one embodiment,
between the connectors 228 on the opposite sides of the back support provides
relative stability to the upper portion of the back support 212, which resists
rotation or torsional movement about a longitudinal axis 2 or fore-aft bending
or
flexing. In contrast, the centrally located rear link 25, and the overall
width (W3)
thereof, which is the only support for the bottom of the back support 212,
allows
for rotation or torsional movement of the bottom 224 of the back support
relative
to the top of the back support about a longitudinal axis 2', with the rotation
or
torsional movement of the top of the back support being restricted as
previously
explained. In one embodiment, the ratio of W2 to W3 is about 2:1 or greater.
[00207] The lower portions 214, 226, or support arms, of the back frame
and
back support are vertically spaced and define an open lateral pass through
therebetween, notwithstanding that both support arms pivot about the same flex
region 31 due to their common connection to the vertically extending and rigid
rear link 25.
[00208] In addition, because the seat support 6 and back support 212 are
separate, and independently connected to the rear link 25 and therefore
independently pivotable relative to the rear link 25, side-to-side rotation of
the rear
portion of the seat, and bottom of the back support, are not restricted by a
connection to each other. In other words, the rear of the seat assembly 8 is
not
directly connected to the back support 212, but rather the seat assembly 8 and
back
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support 212 are only interconnected through the centrally located rear link
25,
such that the rear of the seat assembly 8 and the bottom of the back support
212
are independently rotatable about their respective longitudinal axes 2, 2'.
Likewise, the back frame 210 is also supported at a lower portion 214 thereof
by
the centrally located rear link 25.
[00209] The back support 212 includes an upper member 230 extending
between and connected to upper ends of the pair of second uprights 222, and
the
bottom portion 224 extends between and is connected to the lower ends of the
pair
of second uprights. The upper member 230, uprights 222 and the bottom portion
224 define a central opening 232. A suspension material 234 is stretched
across
the central opening 232 and is secured to the back support 212 in a similar
fashion
as the seat.
[00210] Specifically, the upper member 230, the bottom portion 224 and
the
pair of second uprights 222 define a support frame 236 having a peripheral
edge
238 as shown in FIG. 7B. A flexible edge member 240 is secured to the
peripheral
edge of the upper member 230 and uprights 222, or along a face of the bottom
portion 224. A carrier frame 242 is coupled to the support frame 236 and
includes
a peripheral groove 244 facing outwardly from a peripheral edge surface or
face
246, oriented horizontally between the front and rear surfaces of the carrier
frame,
which is spaced apart from an inner surface or inwardly facing face 248 of the
flexible edge member 240 and defines a space or gap G therebetween as
disclosed
above with respect to the seat assembly. The groove 244 opens outwardly from
the carrier frame 242 along the peripheral edge 246 thereof. The suspension
material 234 includes at least one stay 250, configured as a ring in one
embodiment, secured along a peripheral edge portion 252 of the suspension
member, wherein the at least one stay is disposed in the groove 244. The stay
250
may be held by friction alone, without any auxiliary support material such as
adhesive. In one embodiment, the stay directly 250 engages one surface, e.g.,
a
front surface, of the groove 244, while the fabric engages the rear surface.
In this
way, as with the seat, the stay engages the surface of the groove 244 closest
to the
surface of the carrier frame covered by the fabric. In one embodiment, the
stay
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250 is formed as a continuous ring having a fixed length, with the stay 250
being
relatively inelastic and resistant to elongation along a length thereof, but
which
may be flexible and bendable.
[00211] In another embodiment, and referring to FIGS. 46, 47, 88 and 89,
the
support frame 236 includes a rear wall 800 defining a body facing surface 802,
an
outer peripheral edge wall 804 having an outer surface 806 and an inner
peripheral
edge 808 wall, with the walls 804, 808 defining a forwardly facing channel
810.
A lip 812, or catch, extends laterally inwardly from the outer peripheral edge
wall
and defines a channel 816 with the rear wall 800, with a rear surface of the
lip
defining an engagement surface 814. As shown in FIG. 88, the lip 812 may be
defined by or include a plurality of tabs 815 spaced apart around the
periphery of
the support frame 236. In one embodiment shown in FIGS. 90 and 91, the portion
of the lip 812 running along the top of the frame has a plurality of spaced
apart
notches 839 or slots, which make the top portion of the carrier frame more
flexible
such that the carrier frame may be more easily installed (e.g., bowed) within
the
support frame. At the same time, the lip 812 (or plurality of tabs 841 defined
by
the slots) remains sufficiently rigid to engage the stay attached to the
periphery of
the fabric suspension material that is wrapped around the carrier frame, with
the
stay secured in the groove 816. A carrier frame 820 has a body with a rear
flange
822 defining a rear surface overlying and engaging the rear wall and an insert
portion 824, defined by a plurality of tabs 825 spaced apart around the
periphery
of the carrier frame 820 in one embodiment.
[00212] The insert portion 824 is received in the channel 816 and
engages the
engagement surface 814. The carrier frame 820 further includes upper and lower
pairs of lugs 827 that are aligned with lug 829 on the support frame 236, with
fasteners 831 securing the lugs 827, 829 to further connect the support frame
236
and carrier frame 820. The carrier frame 820 includes a second flange 826 that
forms an outwardly facing groove 830 with the flange 822 and defines an outer
peripheral edge wall 827. The flange 826 extends across the channel 810 with
an
edge 832 positioned adjacent the inner peripheral edge wall 808 and closing
the
channel. Tension applied by the textile material, configured as a suspension
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material 150 in one embodiment, thereafter applies a moment to the carrier
frame
820 causing it to bear up against the bottom surface of the support frame and
the
engagement surface. A flexible edge member 240 is coupled to the outer surface
of the peripheral edge wall 804 of the support frame, with a lip portion
overlying a
top surface of the support frame. The flexible edge member 240 has an inner
surface spaced apart from and facing inwardly toward the peripheral edge wall
of
the carrier frame, with the inner surface and the peripheral edge wall 827 of
the
carrier frame defining a gap therebetween. A portion of the textile material
is
disposed in the gap, with the textile material covering the peripheral edge
wall 827
and body facing surface of the carrier frame. The peripheral edge of the
textile
material is secured to a stay 156, with the edge portion of the textile
material and
the stay disposed in the groove 830. The carrier frame 242 may be secured to
the
support frame with the overlapping tabs 815, 825 and fasteners 831, including
mechanical fasteners and/or adhesive.
[00213]
Referring to FIGS. 29-36, 54A and B, and 55, another embodiment
of a backrest assembly 700 includes a back support 702 having first and second
laterally spaced uprights 704 each having upper and lower portions 706, 708
defining separate first and second forwardly facing convex curvatures/curved
surfaces 710, 712, and a cross member 714 extending between and coupled to the
uprights at the junction between the upper and lower portions 706, 708. The
upper
and lower portions may each include a cross member portion 713, 715, which
with
the upper and lower portions being joined, and having overlapping flanges, to
define the overall cross member 714. The upper and lower portions define a
forwardly facing concave curved surface 711 at the junction thereof. A
suspension material 150, preferably configured as a single piece of material
or
blank, is connected to the first and second uprights 704 and spans across the
central opening therebetween, the suspension material having a front surface
and a
rear surface. At least opposite side portions 716 of the suspension material
bear
against and follow the contour of the upper and lower portions 706, 708,
including
having first and second forwardly facing convex curvatures overlying and
mating
with the front surface of the uprights, and concave curvature overlying the
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junction. A laterally extending stay 718 is coupled to the suspension material
and
extends between the rear surface of the suspension material and the cross
member
714 so as to pull the suspension material 150 rearwardly toward the cross
member
718 and thereby define a seam 717 and provide forwardly facing convex and
concave curvatures along a central portion of the suspension material
laterally
spaced, and at an intermediate location, relative to the uprights. The
periphery of
the suspension material is connected to the back support with a stay as
disclosed
herein elsewhere, for example in FIGS. 46 and 47. The lower portion 708 of the
uprights 704 are connected to the back frame uprights 218 with connectors 228
as
disclosed herein elsewhere.
[00214] The cross member 718 has a forwardly facing and laterally
extending
slot 720 and a laterally extending cavity 722 disposed rearwardly of the slot.
The
stay 718 has a head portion 724 disposed in the cavity and a neck portion 726
extending through the slot. The stay is sewn to the suspension material. The
stay
comprises a first thinned region 728 formed along a length thereof, wherein
the
stay is sewn to the suspension material along the thinned region. The stay is
resiliently bendable. In a pre-installation configuration, the stay has a flat
surface
732 that lies flat against the suspension material, such that the suspension
material
and stay may be easily translated and processed under a sewing machine. The
neck portion is connected to the head portion adjacent a second thinned region
730, which defines a flex region. The head portion includes a catch member
734,
which extends upwardly from the flat surface. After the stay is secured to the
fabric, the stay may then be bent with the head portion 724 rotatable relative
to the
neck portion from an insert position, wherein the head is insertable through
the
slot 720, to a retention position, wherein the head portion, and catch member
734
in particular, is retained in the cavity and the catch portion engages one or
more
edges of the channel 720.
[00215] Referring to FIGS. 57-59, a lumbar support 900 includes a
central
pad 902, one or more elastic straps secured to the pad and extending laterally
outwardly therefrom, and a hook 906 secured to the end of each strap. The
hooks
906 are wrapped around the outer edge of the back support and slide there
along to
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various vertical positions as desired by the user. A pair of inner pads 904
are
disposed and slide along an inner surface of the support, and help maintain
engagement of the hooks on the support. Due to the resilient/elastic nature of
the
straps, the hooks may move inboard/outboard relative to the pad to accommodate
different dimensions between the uprights 222. In addition, the elastic straps
allow for the hooks to rotate, for example as they slide along curved portions
of
the uprights and/or lower portion of the back support.
[00216] In an alternative embodiment, shown in FIGS. 96-99B, a lumbar
support 1100 is connected to the pair of uprights 222 defining a part of the
frame
across the opening. The lumbar support extends between the uprights and has a
pair of hooks 1102 connected to opposite ends of the lumbar. Due to the
elastic
connection between the lumbar and the hooks, the hooks may pivot or rotate
relative to the lumbar, allowing the hooks to follow the curved contour of the
frame uprights 222 while the lumbar remains taught across the opening, as
shown
for example in FIGS. 99A and B, with the lumbar support 1100 in high and lower
positons respectively. The lumbar support has a central pad 1104 with a pair
of
grooves 1106 extending along the upper and lower edges thereof. A looped band
1108 includes upper and lower cords 1110, 1112 positioned in the grooves, with
looped end portions 1114 extending from and joining the upper and lower cords.
The looped end portions are disposed in a U-shaped groove 1116 formed on an
inboard end, or hub 1118, of an adapter 1120. The hub has a pair of spaced
apart
lips 1122 that define in part the groove and retain the end portions 1114 in
the
groove. The end portions 1114 are tucked or press-fit into the groove, with
the
lips 1122 holding the end portions. The adapter includes an insert portion
1124, or
flange, with a flexible tab 1126, or detent, extending transversely from the
flange.
The insert portion 1124 extends laterally from the hub and is inserted into a
passage 1128 in the end of the hook. The adapter includes a shoulder 1130
defined at a junction of the hub and insert portion that engages an inboard,
abutment surface 1132 of the hook defined by an inboard wall or flange. An
outboard surface 1134 of the wall has a pair of angled surfaces defining an
apex,
or pad, which engage an inboard surface of the frame uprights 222, but allows
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sliding relative thereto while helping maintain engagement with the uprights.
The
tab 1126 snaps into engagement with an opening 1136 formed in the hook that
communicates with the passage. In this way, the central pad 1104 is coupled to
the pair of hooks 1102. The looped band, including the upper and lower cords,
allows the hook 1102 to rotate slightly relative to the pad 1104, for example
when
the lumbar is moved along a lower portion of a backrest frame uprights, which
are
tapered inwardly toward a centerline as shown in FIG. 99B. The looped band
1108 is flexible, with the cords 1110, 1112 being slightly pretensioned when
the
hooks are engaged with the outer edge of backrest frame. Due to the
pretension,
the lumbar support 1100 remains engaged with the frame even as the width
dimension thereof is diminished as the lumbar support moves toward the bottom
of the backrest.
[00217] Referring to FIG. 96, the central pad 1104 (e.g., printed or
foam
pad) may be fitted within an elastic sleeve. Ends of the sleeve may be coupled
to
the adapters, for example the faces thereof, and abuts the end surface of the
hook,
with the hook and sleeve being flush at the junction thereof. The sock is made
of
an elastic material, such as knit material. In this way, the sock provides
both a
pleasing aesthetic appearance while also providing function, namely allowing
the
lumbar to be tensioned, and lengthened or shortened, between the frame
members. The elasticity of the sock maintains tension in the sock even as the
hooks get closer together near the curved bottom of the frame. The front of
the
pad, or the sleeve covering the pad, engages the rear surface of the
suspension
material and provides lumbar support to the user.
[00218] Referring to FIGS. 100-102, the backrest may be configured with
an
adjustable headrest 1000. The headrest includes an (inverted) J-shaped strap
1002,
which forms a hook 1004 that fits over the top of upper portion 706, for
example a
cross member thereof, or over the upper member 230, with a friction/snap fit.
The
hook may have a forwardly extending lip 1010 that fits under and engages a
bottom side of the cross member. The strap has a downwardly extending leg 1006
lying along a front surface of the backrest. The leg includes a mounting
portion
1008, shown as a platform having a pair of fastener openings.
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[00219] The headrest includes an insert frame 1012 having a central
track
1014, with one side of the track having a plurality of indents 1016. A ratchet
block 1018 is inserted in the track. The ratchet block is fixedly coupled to
the leg
mounting portion 1008, or platform, with a pair of fasteners 1020, with the
frame
1012 trapped therebetween. The block 1018 includes a flexible pawl 1028
extending laterally from the block. A cushion 1024, which may be a suspension
material or a foam member covered with fabric, is connected to the frame, for
example by engaging a peripheral groove 1022 extending around the periphery of
the frame. The headrest 1000 is vertically moveable relative to the fixed
ratchet
block 1018, which moves within the track 1014. The flexible ratchet pawl or
arm
flexes laterally, with an end portion engaging at least one of the indents
1016 to
index the headrest on the leg 1006. The headrest 1000 may be gripped and moved
vertically to position the headrest at a desired location along the length of
the
strap, with pawl 1028 flexing in and out of engagement with the indents 1016.
As
shown in FIG. 101, the headrest 1000 has a low profile, and may lie almost
entirely within the concave recess defined between the upright portions of the
upper portion 706.
OPERATION:
[00220] In operation, and referring to FIGS. 18, 19, 21 and 55, a user
101
may sit in the body support structure 10. Depending on the weight of the user,
and
the amount of deflection of the suspension material 150, and the deflection of
the
side portions of the support/carrier frames coupled to the suspension
material, the
suspension material may engage the upper surface 202 of the auxiliary support
member 200, or cushion 203, which thereafter assists in absorbing the load of
the
user. In essence, the side portions are inwardly deflectable a first amount
from a
first unloaded configuration to a first loaded configuration in response to a
load
applied to the elastic material, and define in essence a first spring to
absorb the
load of the user. The elastic textile material, or suspension material 150,
coupled
to the side portions 114 across the opening is downwardly deflectable a second
amount from a second unloaded configuration to a second loaded configuration
in
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response to the load applied thereto, and defines a second spring to absorb
the load
of the user. Stated another way, the deflection of the frame, or side
portions, and
the deflection of the suspension material act in combination to provide a
first
amount of support to the user. The cushion disposed beneath the textile
material
engages and provides auxiliary support to the elastic material when the first
and
second amounts of deflection, or first amount of support, result in the
elastic
material contacting the cushion which defines a Wird spring to absorb the toad
of
the user. The upper surface of the cushion 203 is spaced apart from the
textile
material when the side portions 114 are in the first unloaded configuration
and the
elastic suspension material 150 is in the second unloaded configuration. In
this
way, the flexible support/carrier frame, elastic suspension material and
cushion
provide first, second and third amounts of resilient support to a user
engaging and
supported by the textile material, with the suspension material and flexible
frame
working in combination. It should be understood that the elastic suspension
material 150 is downwardly deflectable a first amount in response to the
deflection
of the at least one side portion 114, or both side portions depending on where
the
load is applied.
[00221] The resilience and deflection of the side portions 114 is
primarily a
function of the deflection of the at least one connector 80, 108 extending
between
the central portion 102 and support platform 30 and the side portions 114. The
connectors 80, 108 extend upwardly and outwardly from the central portion, and
curved with an upwardly facing concave surface such that is rigid and resists
outward/downward deflection/deformation. As noted above, the connectors 80,
108 includes a pair of opposite side connectors that are inwardly deflectable
from
the first unloaded configuration to the first loaded configuration in response
to the
load applied to the elastic material.
[00222] The user 101 may recline, with the tilt control assembly 18
providing
for the seat and/or backrest assemblies 8, 6 to move rearwardly, whether by
pivoting, rotation, translation or a combination thereof, for example by way
of a
four-bar mechanism including links 8, 23, 25 and 33.
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[00223] Referring to FIGS. 18, 19 and 21, as the seat assembly 8 tilts
or
reclines rearwardly, the support platform 30 and the carrier frame 100 flex or
bend
about the flex regions 53, 153, such that the rear portion 121 of the seat
assembly,
and rear portion of the support platform, rotates or deflects downwardly
relative to
the front portion 123 of the seat assembly, and front portion of the support
platform, about the flex region. At the same time, and due to the geometry of
the
seat assembly, including the configuration of the outer ring 104, the geometry
of
the connectors 108, the concavity of the carrier frame 100, and the
configuration
of the openings 109, 119, the intermediate connectors 108 flex or bend
upwardly
about flex regions 155, such that the side member 114 of the outer ring 104
move
upwardly relative to the support platform and inwardly toward each other to a
new
configuration or shape of the side member 114', with the textile material 150
assuming a more concavely configured textile material 150' that slightly
hammocks and hugs the user. As the connectors 108 and outer ring 104 deflect,
the overall length of the outer ring 104 is maintained, and is not increased.
It
should be understood that referring to the side members 114 moving upwardly is
relative to the support platform 30, which in part may be moving downwardly,
such that the overall or absolute movement of the side members relative to
ground
is negligible. The support ring 48 is sufficiently flexible and compliant that
the
support ring 48 does not interfere with the flexing of the carrier frame 100,
but
rather provides a decorative and tactile skin covering a bottom surface of the
carrier frame. If needed, the support ring 48 may also be provided with flex
regions to allow such flexing. Due to the geometry of the seat assembly,
including
the configuration of the outer ring 104, the geometry (e.g., upwardly
concavity) of
the curved connectors 108, the concavity of the carrier frame 100, and the
configuration of the openings 109, 119, the side members 114 and connectors
108
are relatively rigid, and resist/avoid a downward deformation, in response to
downward load applied along the sides of the seat at the perimeter of the
chair.
[00224] As the user reclines, the back frame 218 tilts rearwardly with
the rear
link 25, with the back support 212 also tilting with the rear link 25. At the
same
time, and in response to a load applied to the backrest by the user, the back
support
CA 03164328 2022-06-10
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212, and the lower portion 226 and uprights 222 in particular, will flex about
the
flex regions 225, 231 respectively, while pivoting relative to the back frame
218
by way of the connectors 228. In particular, the flex region 225 of each
upright
222 adjacent the lumber region will bend or flex to provide more support at
the
lumbar, while the lower flex region 231 accommodates and permits the flexing
of
the lumbar region. At the same time, the connectors 228 above the flex region
225
permit rotation of the back support 212, and the uprights 222 in particular,
relative
to the back frame 210 and uprights 218 to accommodate the flexing of the
lumbar
region.
[00225] Due to the orientation of the front and rear links, and relative
positioning of the flex regions 27, 53, which are disposed upwardly and
forwardly
of the flex regions 29, 31 respectively, the four-bar linkage provides a
weight
activated system, meaning the weight of the user is taken into account when
reclining since the increase in potential energy is offset by the kinetic
energy
required to recline. In this way, the four-bar mechanism will provide more
resistance to a heavier user and automatically counterbalance the user. As
noted
previously, the amount of recline may be limited by the recline limiter, while
energy may supplied to boost the resistance to recline and return the body
support
assembly to the upright, nominal position.
[00226] Although the present invention has been described with reference
to
preferred embodiments, those skilled in the art will recognize that changes
may be
made in form and detail without departing from the spirit and scope of the
invention. As such, it is intended that the foregoing detailed description be
regarded as illustrative rather than limiting and that it is the appended
claims,
including all equivalents thereof, which are intended to define the scope of
the
invention.
