HK40056614A

HK40056614A - Body support assembly and method for the use and assembly thereof

Info

Publication number: HK40056614A
Application number: HK62022045728.2A
Authority: HK
Inventors: 尼科劳斯·威廉·查尔斯·迪维尔斯; 库尔特·R·海德曼; 戈登·J·彼得森
Original assignee: 斯特尔凯斯公司
Priority date: 2019-02-21
Filing date: 2020-02-19
Publication date: 2022-04-01

Description

Body support assembly and methods for use and assembly thereof

This application claims the benefit of U.S. provisional application No.62/808,579 filed on day 21, 2, 2019 and also claims the benefit of U.S. provisional application No.62/947,914 filed on day 13, 12, 2019, both entitled "Body Support Assembly and Methods for the Use and Assembly of a Body Support Assembly", the entire disclosures of which are incorporated herein by reference.

Technical Field

The present application relates generally to body support assemblies, such as chairs, and in particular to a back assembly and/or a seat assembly incorporated into a body support assembly and various components incorporated into a body support assembly, as well as methods for use and assembly of the body support assembly.

Background

Chairs, and particularly office chairs, may have a body support member configured with a suspension material, such as a mesh fabric, stretched across a frame. Such a suspension material conforms to the body of the user, provides micro-compliance while improving air circulation and, in turn, heat dissipation benefits. Typically, the frame must be rigid to maintain a proper level of tension in the suspended material. However, such rigidity may limit the flexibility of the body support member and introduce intolerable pressure points around the perimeter of the frame. Furthermore, the suspension material mounted on the seat portion of the chair is typically required to maintain a high tension due to the load applied to the suspension material by the seated user, which may deteriorate the limited flexibility and rigidity of the support structure.

While various mechanical systems, such as lumbar supports and tilt control mechanisms, may be incorporated to alleviate the limited flexibility and provide additional adjustment capabilities, such systems are relatively expensive to manufacture, require additional maintenance, are subject to wear over time, and may not be properly utilized by the user due to the need for individual adjustment. Furthermore, such tilting mechanisms typically include one or more rigid links and mechanical linkages that are rigid and non-compliant, which results in a more rigid and less tolerable ride, and which may result in a less desirable user experience. Conversely, systems that rely on the material properties of the seating structure to introduce appropriate kinematics and flexibility may not be suitable for supporting suspended materials. While the body support surface may be defined by one or more foam pads, the foam material may restrict air circulation and often does not provide localized support. In addition, body support members configured with a plastic shell, such as supported by a perimeter frame, often do not provide a comfortable body conforming support surface.

Disclosure of Invention

The present invention is defined by the following claims, and nothing in this section should be taken as a limitation on those claims.

In one aspect, one embodiment of the 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 and extends radially outward from the first peripheral edge of the lower support platform, and the support ring defines a second peripheral edge. The support ring includes an upper surface. An upper shell is disposed on an upper surface of the lower support platform and an upper surface of the support ring, and the upper shell defines a concave cavity. The upper shell has a third peripheral edge defining a central opening and has an upper surface. The suspension material is secured to the upper shell across the central opening and covers the concave cavity.

In another aspect, one embodiment of a body support member includes a carrier frame having a first body facing surface, a second surface opposite the 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. The support frame includes a first surface and a peripheral edge. The flexible edge member is connected to the peripheral edge of the support frame. The flexible edge member has an inner surface spaced from and facing the perimeter edge surface of the carrier frame. A gap is defined between the inner surface and the peripheral edge surface, wherein the gap is in communication with the peripheral groove. The 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 rim and the peripheral rim surface of the carrier frame. The textile material engages at least a portion of the peripheral edge surface of the carrier frame. A peripheral edge of the textile material is disposed in the peripheral groove.

In another aspect, one embodiment of a method of making a body support member comprises: the method includes providing a peripheral edge of a textile material into a groove formed in a peripheral edge surface of the carrier frame, covering at least a portion of the peripheral edge surface of the carrier frame 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 from and facing the perimeter edge surface of the carrier frame, wherein a gap is defined between the inner surface and the perimeter edge surface, wherein the gap is in communication with the perimeter groove, and wherein the textile material is disposed in the gap.

In another aspect, one embodiment of the seat assembly includes a lower support platform extending in a longitudinal direction. The lower support platform includes opposing side edges and a laterally extending first flexure region extending between the opposing side edges that bifurcates the lower support platform into a front and a rear. The first flex region is bendable such that the rear portion is deflectable downward relative to the front portion, even though in one embodiment both the front and rear portions may move upward during recline. The upper shell includes opposing side members connected to the support platform by a pair of connectors. Each of the connectors includes a second flex region, wherein the second flex region is bendable such that the opposing side members are movable upward relative to the lower support platform when the rear portion is deflectable downward.

In another aspect, a body support member includes a carrier frame having a central portion and a peripheral ring connected to the central portion by a plurality of connectors, the connectors each having a flex region, wherein the peripheral ring defines a central opening. An elastic textile material is coupled to the peripheral ring across the central opening. The pad is disposed between the central portion and the textile material. At least one connector of the plurality of connectors is deflectable inwardly a first amount from a first unloaded configuration to a first loaded configuration in response to a load applied to the resilient material, and the resilient material is deflectable downwardly a second amount from a second unloaded configuration to a second loaded configuration in response to the load applied to the resilient material. When the first amount of deflection and the second amount of deflection cause the resilient material to contact the pad, the pad engages the resilient material and provides additional support to the resilient material.

In another aspect, one embodiment of a body support member comprises: a flexible carrier frame deformable from an unloaded configuration to a loaded configuration; an elastic textile material coupled to the carrier frame; and a pad disposed below the textile material. The flexible carrier frame, the resilient material, and the cushion provide a first amount, a second amount, and a third amount of resilient support to a user engaging and being supported by the textile material.

In another aspect, one embodiment of the body support member includes a carrier frame having opposing side portions defining an opening therebetween. An elastic textile material is coupled to the side portion across the opening, wherein the pad is disposed below the textile material. At least one of the side portions, preferably both side portions, is inwardly deflectable from a first unloaded configuration to a first loaded configuration by a first amount in response to a load applied to the elastic material. The resilient material is capable of deflecting a second amount downward from a second unloaded configuration to a second loaded configuration in response to a load applied to the resilient material, and the pad engages and provides additional support to the resilient material when the first amount of deflection and the second amount of deflection cause the resilient material to contact the pad.

In another aspect, one embodiment of the body support assembly includes a seat having opposing sides spaced apart in a lateral direction and front and rear portions spaced apart in a first longitudinal direction.

Various methods of using and assembling the body support assembly and other components are also provided.

Various embodiments of body support assemblies and components and methods for use and assembly of the same provide significant advantages over other body support assemblies and methods. For example and without limitation, this structure allows for the incorporation of suspension materials into the back and/or seat while maintaining the overall flexibility of these components. The structure and user interface provide a body support structure that conforms to the user's body during use and provides macro compliance, while also providing micro compliance at the user interface and avoiding a hard interface around the perimeter of the structure.

In addition, the various linkages and flexure regions provide a simple yet robust structure that ensures proper fit for numerous users without the need for complex mechanical mechanisms and adjustment interfaces. The body support assembly and its various flex regions and material conformability provide increased comfort and fit while reducing costs by reducing and/or eliminating the overall number of components, including various metal components, which can reduce manufacturing costs. In addition, the compliant material can reduce the overall weight of the body support assembly and the transportation costs associated therewith. The body support assembly is uncomplicated, durable, visually pleasing, and has a long service life.

The above paragraphs are provided by way of general introduction and are not intended to limit the scope of the claims set forth above. 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.

Drawings

Figure 1 is a perspective view of one embodiment of a body support assembly.

Figure 2 is a right side view of the body support assembly shown in figure 1 wherein the left side view is a mirror image of the right side view.

Figure 3 is a front view of the body support assembly shown in figure 1.

Figure 4 is a rear view of the body support assembly shown in figure 1.

Figure 5 is a bottom view of the body support assembly shown in figure 1.

Figure 6 is a top view of the body support assembly shown in figure 1.

Fig. 7A, 7B and 7C are partial cross-sectional views of a body support member.

Fig. 8 is a partial perspective view of the seat, with the textile material not shown for the purpose of illustrating the underlying components.

Figure 9 is a top view of one embodiment of a seat support structure without the textile material or carrier frame shown to illustrate the underlying components.

Figure 10 is a bottom perspective view of one embodiment of a lower seat support platform.

FIG. 11 is a right side view of the support platform shown in FIG. 10, wherein the left side view is a mirror image of the right side view.

Fig. 12 is a rear view of the support platform shown in fig. 10.

Fig. 13 is a top view of the support platform shown in fig. 10.

FIG. 14 is a left side view of an embodiment of a support ring, wherein the right side view is a mirror image of the left side view.

Figure 15 is a top view of the support ring shown in figure 14.

Figure 16 is a side view of one embodiment of an upper seat shell.

Fig. 17 is a top view of the upper housing shown in fig. 16.

Figure 18 is a schematic side view illustrating the deflection of the seat assembly during recline.

Fig. 19 is a schematic front view illustrating the deflection of the seat assembly during recline.

Figure 20 is an exploded view of the seat assembly.

Fig. 21 is a schematic view showing a four-bar mechanism supporting the seat assembly.

Figure 22 is a partial cross-sectional view of the front of the seat assembly.

Figure 23 is a partial cross-sectional view of the side of the seat assembly.

FIG. 24 is a partial cross-sectional view of the top of the back support.

Figure 25 is a partial cross-sectional view of the side of the back support.

Fig. 26 is a flow chart illustrating assembly of the seat assembly.

Figure 27 is a partial plan view of the textile material installed on the seat assembly and back support.

Fig. 28A to 28D are bottom, top, exploded and enlarged cross-sectional views illustrating the connection between the front link and the seat assembly.

FIG. 29 is a partial view of one embodiment of a stent.

Figure 30 is a partial cross-sectional view of the seat assembly.

Detailed Description

It should be understood that the term "plurality" as used herein refers to two or more. The term "longitudinal" as used herein refers to or refers to a length or lengthwise direction 2, 2', such as a direction extending from the bottom of the back assembly 6 to the top of the back assembly 6, or from the top of the back assembly 6 to the bottom of the back assembly 6, or from the front of the seat assembly 8 to the rear of the seat assembly 8, or from the rear of the seat assembly 8 to the front of the seat assembly 8. The term "transverse" as used herein refers to a direction that is located, directed or extends in the left-right direction 4 of the body support assembly 10, which body support assembly 10 is shown in one embodiment as an office chair including a back assembly 6 and a seat assembly 8. It should be understood that the body support assembly may be configured as any body supporting structure including, but not limited to, automobiles, aircraft and mass transit seating, beds, household items (including sofas and chairs), and other similar and suitable structures. In one embodiment of the backrest assembly disclosed below, the transverse direction 4 corresponds to the horizontal direction and the longitudinal direction 2 corresponds to the vertical direction, while in one embodiment of the seat assembly, the longitudinal direction 2' corresponds to the horizontal direction. The transverse direction 4 may be referred to as the X-direction, while the longitudinal directions 2, 2' refer to the Y-direction, and the Z-direction is orthogonal to the body support surfaces of both the back assembly 6 and the seat assembly 8.

The term "coupled" means connected to or engaged with directly or indirectly, such as through an intermediate member, and does not require that the engagement be fixed or permanent, even though the engagement may be fixed or permanent. As used herein, the terms "first," "second," and the like, are not meant to be assigned to the particular component so designated, but simply refer to such component in the order of the numerical values set forth, which means that the component designated as "first" may thereafter be the "second" component, depending on the order in which the components are referenced. It will also be understood that the designation "first" and "second" does not necessarily mean that the two components or values so designated are different, which means that, for example, a first direction may be the same as a second direction, where each direction may simply apply to different components. The terms "upper," "lower," "rear," "front," "rear," "vertical," "horizontal," "right," "left," as well as variations or derivatives of these terms, refer to the orientation of the exemplary body support assembly 10 shown as a chair in fig. 1-6 as seen from the perspective of a user seated in the body support assembly 10. The term "transverse" means non-parallel. The term "outwardly" refers to a direction away from a central location, e.g., the phrase "radially outwardly" refers to a feature that is offset from a central location, e.g., a middle or interior region of a seat or backrest, and generally lies in the XY plane defined by the lateral and longitudinal directions 2, 2', 4. It should be understood that features or components that face or extend "outwardly" do not necessarily originate from the same central point, but rather generally emanate outwardly and outwardly along non-tangential vectors. Conversely, the term "inwardly" refers to a direction facing toward a central or interior location.

The term "textile material" refers to a flexible material made of a web of natural or artificial fibers (yarns, monofilaments, threads, etc.). The textile material may be formed by weaving, knitting, crocheting, knotting, felting or braiding. The textile material may comprise: can be used for example for covering various furniture upholstery materials for foam cushions; and/or a suspension material that can be stretched across the opening or placed under tension to support the user.

A body support assembly:

referring to fig. 1-6, the body support assembly 10 is shown to include a tilt control assembly 18, also referred to as a lower support structure, a base structure 12, and a back assembly 6 and a seat assembly 8. In one embodiment, the base structure 12 includes a leg assembly 14 and a support post 16, the support post 16 being coupled to and extending upwardly from the leg assembly. The tilt control assembly 18 is supported by and coupled to the top of the support column 16. The leg assembly may alternatively be configured as a fixed structure, such as a four-legged base, a ski base, or other configuration. In one embodiment, the support column 16 may be height adjustable, including for example and without limitation, a telescoping column with pneumatic, hydraulic, or electromechanical actuators. The leg assembly 14 includes a plurality of support legs 22 extending radially outward from a hub 24 surrounding the support post. The end of each support leg may be equipped with a caster, slide or other floor contacting member 20.

In the embodiment of fig. 1-6, a pair of armrest assemblies 26 are coupled to the tilt control assembly 18. Various user interface controls 28 are provided for actuating and/or adjusting the height of the seat, including, for example, an actuating lever pivotally coupled to the armrest assembly, or for controlling the tension and/or return force of the tilt control assembly 18.

The tilt control assembly:

referring to fig. l-6 and 28A-28D, the back and seat assemblies 6,8 are operatively coupled to a tilt control assembly 18 or lower support structure that controls movement of the back and seat assemblies 6,8, such as during recline. One embodiment of a suitable tilt control Assembly is disclosed in U.S. patent No.9,826,839 entitled "Chair Assembly with decorative Covering," the entire disclosure of which is hereby incorporated by reference herein. The tilt control assembly may include a plurality of rigid control links that may be mechanically connected, such as via pivot pins, to form a linkage assembly including, for example, a four-bar linkage.

In other embodiments, the tilt control assembly includes integrally formed links 23, 25, 33, the links 23, 25, 33 being configured, for example, to have strategically deformable positions that allow for predetermined deformation and define a "flex zone" or virtual pivot location otherwise referred to as a "flex link". The various configurations of the links and flex regions may be constructed as shown and disclosed in U.S. patent publication No.2016/0296026 a1 entitled "setting Arrangement" and U.S. patent publication No.2018/0352961 entitled "setting Arrangement and Method of Construction," the entire disclosures of which are incorporated herein by reference.

For example, the tilt control assembly 18 may be configured as a four-bar mechanism as shown in fig. 21, wherein the bottom or base link 33 is connected to the base structure 12 at a first location, and the front and rear links 23, 25 are connected between the base link and the seat assembly 8. Base link 33, front link 23, and rear link 25 define a lower support structure. For example, front link 23 and rear link 25 may be pivotally or bendably connected to 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 the flexure zones 27, 53, wherein a portion 57 of the seat assembly extending between the flexure zones 27, 53 defines a link of a four-bar mechanism. The flex region 53 is formed in the support platform 30 portion of the seat assembly. The various flexure zones 27, 29, 31, 53 may be formed as living hinges or as thin flexible hinges made of the same material as the two more rigid components to which the living hinges are attached to provide relative rotation or pivoting between the more rigid components through bending of the living hinges. It should be understood that in alternative embodiments, the links and rods of the mechanism may also be configured as rigid links and rods connected at fixed articulation points.

In operation, a user may move or recline the back assembly 6 and the seat assembly 8 from an upright position to a reclined position by flexing the four-bar mechanism, including the portion of the seat assembly. It is contemplated that the four-bar linkage arrangements used and described herein include linkage arrangements having 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 in particular front link 23, base link 33, and seat link 57, as well as predetermined flex regions of these links 23, 25, 33, 57, may be positioned to achieve desired performance characteristics, including, for example, flexibility of the links. Further, in certain embodiments, the thickness of the link may vary along the length of the link to achieve a desired flexibility or stiffness across the link or in localized portions of the link, such as at flexure regions 27, 28, 31, and 53. Additionally, and for example, the front link 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 link is substantially flexible in that localized area and substantially inflexible or less flexible in any other area of the link. It is noted that the opposite regions of reduced thickness may extend along a short distance or a large portion of the length of the associated link, depending on the desired support and bending characteristics.

A seat assembly:

referring to fig. 1-7C, 8-25, and 28A-28D, the seat assembly 8 is operatively coupled to the tilt control assembly 18 and supports the seating surface 28. The seat has opposite sides spaced apart in the transverse direction and front and rear portions spaced apart in the first longitudinal direction. The seat assembly includes a lower support platform 30, the 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) having a front edge 38, a rear edge 40, and side edges 42 joining the front and rear edges. The rear edge is shorter than the front edge. Peripheral edge 32 may be stepped, meaning that peripheral edge portion 66 of peripheral edge 32 is thin along a central portion 68 of peripheral edge 32.

The support platform 30 has a pair of laterally spaced apart pads 44 positioned at a forward portion of the support platform. As shown in fig. 28A-28D, 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, the hinge portion 976 having a front edge 978, the front edge 978 being secured to a front edge 980 of the platform defining an opening 972 in the platform. The hinge portion may be formed by overmolding a more flexible material to the support platform. Hinge portion 976 extends rearwardly in the opening with a rear edge 982 spaced from a rear edge 984 of the platform defining opening 972. Each of the pads 44 includes at least one mounting feature, shown as an opening 46, the opening 46 being shaped and dimensioned to receive a mounting member (e.g., a fastener or stud 988) for securing the platform to a tilt control assembly, which may include a flange 990 extending forward from the link 23 to support the platform. Flange 990 is received in recess 972, and flange 990 includes a boss that extends upwardly into opening 46 such that flange 990 may be secured to the bottom surface of the pad, particularly hinge portion 976, by a plurality of fasteners 988. The flexible hinge portion 976 defines a flex region 27. The mounting members and the connection to the links 23 allow the support platform and the front link 23 to pivot relative to the base link 33 about the flex region 29 and the seat assembly 8 to pivot relative to the front link 23 about the flex region 27, in both cases pivoting being performed, for example, by elastic deformation or bending of the portions of the front links at the flex regions 27, 29, or alternatively by bending or flexing of the pad or hinge portion 976. At the same time, the spacing between the pad and the front link provides relative stability for the front portion of the seat against rotational or torsional movement about the longitudinal axis. A boss formation 49 extends downwardly from the rear of the support platform. The boss structure 49 defines at least one mounting feature connected to the tilt control assembly 18, and/or defines a portion of the rear link 25 that partially forms the tilt control assembly, and allows the support platform and the rear link 25 to pivot relative to the base link 33 about the flexure region 31, which may be performed, for example, by elastic deformation or bending of the portion of the base link 33 at the flexure region 31. In one embodiment, the boss structure 49 has a tubular configuration defining a cavity that surrounds or receives the insertion portion of the rear link 25, configured to have features from the connectors 479, 219. The centrally located rear link, which is the sole support for the rear of the seat, allows rotational or torsional movement of the rear of the seat relative to the front of the seat about the longitudinal axis, with the rotational or torsional movement of the front being limited as previously described. The support platform 30 has a generally concave upper surface 34 with forward and aft portions 35, 37 extending upwardly from the boss structure.

The support platform may be made of a flexibly resilient polymeric material, allowing the support platform to conform and move in response to forces applied by a user, such as: any thermoplastic including, for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermoset material including, for example, epoxy; or any resin-based composite material including, for example, carbon fibers or glass fibers. Other suitable materials may also be utilized, such as: metals including, for example, steel or titanium; plywood; or a composite material comprising plastic, a resin-based composite material, metal and/or plywood. The support platform may have strategically positioned tension bases, made, for example, of glass reinforced tape to accommodate bending and deformation of the structure. Strategic locations on the lower support platform are also provided with specific geometries that allow for predetermined deformations and define "flex zones" or virtual pivot locations otherwise known as "flex joints".

For example, the support platform may include a region of reduced thickness defining a laterally extending flexure region or zone 53 in the front of the boss structure 49, the flexure region 53 dividing or branching the support platform into a front portion and a rear portion, which may be of different lengths or sizes, wherein the rear portion is deflectable downwardly relative to the front portion as the flexure region bends during recline. The portion of the support platform extending between the flexure region 53 and the flexure region 27 defines the links of the four-bar mechanism, while the portion of the support platform located behind the flexure region 53 partially defines a portion of the rear link 25. It is noted that the opposite regions of reduced thickness may extend along a short distance or a substantial portion of the width of the support platform, depending on the desired support and bending characteristics. The phrase "flexure zone" refers to a portion of a structure that allows flexing or bending in a designated area, thereby allowing or providing relative movement (e.g., pivoting) of components or structures on opposite sides of the flexure zone, thereby defining a virtual pivot location such as a horizontal pivot axis, wherein it is to be understood that the virtual pivot axis may move during flexure, rather than being defined as a hard fixed axis. The various configurations and materials of the support platform may correspond to the configurations and materials of the various components shown and disclosed in U.S. patent publication No.2016/0296026 a1 entitled "sitting Arrangement" and U.S. patent publication No.2018/0352961 entitled "sitting Arrangement and Method of Construction," the entire disclosures of which are incorporated herein by reference.

The support ring 48 has an inner ring 50, the inner ring 50 having an inner peripheral edge 52 defining a central opening 54. The inner peripheral edge 52 surrounds and is coupled to the outer peripheral edge 32 of the support platform that is received in the opening 54, i.e., the rear edge 40, the front edge 38, and the side edges 42 of the support platform 30. 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 that define the opening 54. The inner peripheral edge 52 may be stepped, meaning that a peripheral edge portion 70 of the inner peripheral edge 52 is thinner than a central portion 72 of the inner peripheral edge 52, wherein the edge portion 70 overlaps and mates with the edge portion 66 of the lower support platform. As shown in fig. 7A, the rim portion 70 is positioned above the rim portion 66 with the upper surface of the peripheral rim 52 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 the support ring 48 define, in combination, a support frame 62.

In one embodiment, support ring 48 further includes an outer ring 74, outer ring 74 having side members 76, side members 76 being joined to side members 60 of the inner ring by a pair of front connectors 78 and a pair of middle connectors 80. A pair of rear three-sided openings 81 are defined between the inner edge of outer ring 74, the edges of the side members and the edges of connector 80. The openings 81 each have an inner side 85, a longer outer curved side 87, and a third side 91, wherein the sides 87 and 85 meet along the rear of the opening 81 to define a nose 89, and the third side 91 extends along the connector 80 and defines the connector 80 and joins the sides 85, 87. A pair of front three-sided openings 83 are defined between the inner edge of outer ring 74, the edge of side member 60, and the edge of connector 80. The openings 83 each have an inner side 93, a longer outer curved side 95, and a third side 97, wherein the sides 93, 95 meet along the front of the opening 83 to define a nose 99, and the third side 97 extends along the connector 80 and defines the connector 80 and joins the sides 93, 95.

It should be understood that in one embodiment, the intermediate connector 80 may be omitted. The outer ring has a front cross member 82 and a rear member 58 common to the inner ring and connected to the side members 76. The front cross member 82 is spaced from the front member 56, which defines an elongated and laterally extending U-shaped opening 84 between the front cross member 82 and the front member 56. The 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 the front member 56 when the cross member 82 flexes relative to the front member 56, such as when subjected to loads applied by the user's thighs. The membrane 55 may also act as a limiter by limiting the amount of deflection of the cross member 82 when a load is applied to the membrane 55. The membrane 55 may be made of urethane and may be overmolded onto the support ring 48 to cover the opening 84. The side slots 86 allow the front portions 88 of the side members 76 to flex or bend so that the front members 82 can deflect when loaded by a user's legs, while the connectors 78, 80 provide greater rigidity to the outer ring 74. The outer peripheral rim 90 is stepped, meaning that the peripheral rim portion 92 of the outer peripheral rim 90 is thinner than the central portion 72 of the outer peripheral rim 90. A pair of lugs 94 extend downwardly from the inner ring and are disposed along either side of the boss structure, with the lugs 94 being supported by the tilt control assembly 18. The support ring 48 extends radially outward from the lower support platform 30. The support ring, which includes the outer ring, the inner ring, and the connector, defines an upper surface 96 and a concave cavity 98. The support ring 48 is made of a compliant, flexible material configured to position and retain a flexible edge member 162, which will be described in more detail below. The support ring 48 is less stiff than the support platform and the support ring 48 has a modulus of elasticity less than the modulus of elasticity of the support platform. The support ring may be made of, for example, polyester polyurethane or thermoplastic polyester elastomer.

The upper shell, also referred to as the carrier frame 100, has: a central portion 102, the central portion 102 overlying the inner ring 52 of the support ring and the lower support platform 30; and an outer ring 104, the 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 middle connectors 108 that are curved with a concave curvature facing upward so as to be rigid and resist outward/downward deflection/deformation.

A pair of rear three-sided openings 109 are defined between the inner edge of the outer ring 104, the edge of the central portion 102, and the edge of the connector 108. The openings 109 each have an inner side 111, a longer outer curved side 113, and a third side 117, wherein the sides 111, 113 meet along the rear of the opening 109 to define a nose 115, and the third side 117 extends along the connector 108 and defines the connector 108 and joins the sides 111, 113. A pair of front three-sided openings 119 are defined between the inner edge of the outer ring 104, the edge of the central portion 102, and the edge of the connector 108. The openings 119 each have an inner side 121, a longer outer curved side 123, and a third side 127, wherein the sides 121, 123 meet along the front of the opening 119 to define a nose 125, and the third side 127 extends along the connector 108 and defines the connector 108 and joins the sides 121, 123.

The outer ring 104 has a front cross member 110 and a rear member 112 connected to a side member 114. The outer ring has a circumferential length defined around a perimeter of the outer ring, wherein the length is fixed or remains relatively constant during recline of the seat. In other words, in one embodiment, the outer ring 104 defined by the side members 114, the front cross member 110, and the rear member 112 does not elongate during recline, or undergo elastic deformation along a tangent or length of the outer ring 104 in response to tension, although the outer ring 104 is able to bend or flex as described in more detail below. The front cross member 110 is spaced from the front edge 116 of the central portion 102, which defines an elongated and laterally extending U-shaped opening 118 between the front cross member 110 and the front edge 116 of the central portion 102. The side slots 120 allow the front portions 122 of the side members 114 to flex or bend such that the front cross member 110 can deflect when loaded by a user's legs, while the connectors 106, 108 provide greater rigidity to the outer ring 104. Connectors 106, 108 overlie connectors 78, 80 with openings 84 and 118 aligned with membrane 53. The upper shell includes a pad 124 overlying the pad 46. The upper shell 100 is fixed to the support platform by fasteners including, for example, hooks and screws.

The upper shell or carrier frame 100 is flexible but stiffer than the support rings 48 and has a modulus of elasticity greater than that of the support rings but less than that of the support platforms 30 and less than that of the support platforms 30. The upper shell or carrier frame 100 may be made of a flexibly resilient polymeric material, such as: any thermoplastic including, for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermoset material including, for example, epoxy; or any resin-based composite material including, for example, carbon fibers or glass fibers. Other suitable materials may also be utilized, such as: metals including, for example, steel or titanium; plywood; or a composite material comprising plastic, a resin-based composite material, metal and/or plywood.

The intermediate connector 108 of the upper shell 100 may include a reduced thickness region defining a flex region or flex zone 155. The upper shell 100 may also have a region of reduced thickness defining a flexure region or flexure zone 153, which flexure region or flexure zone 153 overlies the flexure region 53 of the underlying support platform located in the front of the boss structure 48.

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 edge surface 130 or side edge face extending between the first surface 126 and the second surface 128. In one embodiment, the peripheral edge surface 130 is generally planar and has a vertical orientation, but it should be understood that the edge surface may be curved, curvilinear, or non-planar, and/or may be oriented at an angle other than a vertical plane. The carrier frame 100 defines a concave cavity 132 and the outer ring defines a central opening 134.

A peripheral groove 136 is formed in the peripheral edge surface 130 or face 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, the groove 136 extends continuously around the entire perimeter of the carrier frame 100. As shown in fig. 7A-7C, the peripheral edge portion 92 of the support frame 62 extends outwardly beyond the face 130 of the carrier frame. The peripheral groove 136 defines an insertion plane 137, the insertion plane 137 being oriented at an angle α with respect to the peripheral edge surface 130 and with respect to the gap G adjacent to the peripheral edge surface 130. In various embodiments, α is greater than 0 degrees and less than 180 degrees, and preferably between 30 degrees and 120 degrees, and more preferably between 45 degrees and 90 degrees. Defined in another way, the insertion plane 137 is preferably oriented with respect to the landing (landing) portion 144 or a tangent of the textile material 150 supported by the landing portion 144, such that the insertion plane is parallel to the landing portion and the tangent, or forms an angle β, which is preferably between 135 degrees and 180 degrees. The peripheral groove 136 has a pair of spaced apart surfaces, such as an upper surface 138 and a lower surface 140, and has a bottom 142 connecting the surfaces 138, 140. The upper surface 126 of the upper shell has a generally horizontal landing portion 144 and an angled portion 146 extending away from the landing portion and defining a cavity. The land portion 144 may have a width (W) close to 0, wherein the land portion is defined only by the upper corners of the edge surface 130.

The textile material 150 is secured to the carrier frame 100 across the central opening 134 such that the textile material 150 covers the concave cavity 132. The textile material may be a suspension material or may cover a pad supported by the support frame 64 and/or the carrier frame 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 rim surface 130, and in particular an upper portion 152 thereof extending between the groove 136 and the upper surface 126, or the land portion 144 of the upper surface 126. A peripheral rim portion 154 of textile material 150 is coupled to the peripheral rim of the upper shell, for example, wherein the rim portion 154 of the textile material is disposed in the groove 136. In one embodiment, a brace (stay)156 (shown in fig. 20 without the textile material) formed, for example, from a loop (e.g., of plastic or polyester) may be secured to an edge portion of the textile material, such as by adhesive, sewing/stitching, fasteners and other means, or by forming a loop disposed around the brace. In one embodiment, the stent has one surface 158 facing and engaging the textile material and an opposite surface 160 remaining uncovered. A bracket 156 and a rim portion 154 of the textile material configured as a suspension material are disposed in the groove 136 to secure the suspension material under tension across the opening. In one embodiment, the bracket 156 is formed as a continuous loop having a fixed length, wherein the bracket 156 is relatively inelastic and resists elongation along the length of the bracket 156, but the bracket 156 may be flexible and bendable to move with the side member 114 and the outer loop 104 during recline of the seat. In one embodiment, as shown in fig. 7A-7C, the exposed or uncovered surface 160 of the stent 156 directly engages the surface 138 of the groove without any textile material or other substrate disposed between the surface 160 and the surface 138. The angled orientation of the groove 136 and the shelf 156 relative to the edge surface helps ensure that the shelf 156 does not become dislodged from the groove. In one embodiment, the stent 156 and the textile material 150 are inserted into the groove 136 without any secondary fastening system such as adhesive or mechanical fasteners, but are only frictionally engaged when the textile/suspension material is placed under tension as described below.

In another embodiment, and with reference to fig. 22 and 23, 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 inward from the peripheral rim wall 520 and defines a channel 526 with the bottom wall. The lip or catch shown in fig. 23 has an engagement surface 528 along the side portion of the seat, the engagement surface 528 being angled upwardly and inwardly from the peripheral edge wall, while the upper surface of the wall is generally horizontal. The upper surface of the lip shown in fig. 44 angles downwardly and inwardly along the front portion of the seat, while the engagement surface 528 is generally horizontal.

The carrier frame 100 has a body portion 530 with a bottom surface 532 overlying and engaging the bottom wall and an insert portion 534, the insert portion 534 being received in the channel 526 and engaging the engagement surface 528. As shown in fig. 44, the carrier frame has a downwardly and inwardly angled upper surface 536, which upper surface 536 cooperates with the top surface of the lip or catch so that the suspension material can deform relative to the angled surface. As shown in fig. 23, the insertion portion 534 is angled downwardly and outwardly to mate with the engagement surface. The orientation of the insert portion 534 facilitates installation because the insert portion can be more easily inserted into the channel when oriented at an angle such that the insert portion is located below the lip 524. The tension applied by the textile material 150, which in one embodiment is configured as a suspension material, thereafter applies a moment to the carrier frame, causing the carrier frame to bear against the bottom surface of the support frame and the engagement surface 528. The flexible edge member 162 is coupled to the outer surface 522 of the support frame's peripheral edge wall with the lip 538 overlying the support frame's top surface. The flexible edge member 162 has an inner surface spaced from and facing inwardly toward the perimeter edge wall of the carrier frame, wherein a gap is defined between the inner surface and the perimeter edge wall of the carrier frame. A portion of the textile material is disposed in the gap, wherein the textile material covers the body facing surface of the carrier frame. The carrier frame has an outwardly facing peripheral edge 540 and includes a groove 542 that opens laterally outward from the peripheral edge 540. The peripheral edge of the textile material is secured to the bracket 156, with the edge portion of the textile material and the bracket being disposed in the groove 542.

Suspension material:

in one embodiment, the textile material is made of an elastic knitted or braided material and may be configured as a suspension material having heat shrinkable yarns and heat shrinkable elastic monofilaments that shrink in response to application of energy, such as 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, article Textile Fabric, and Products thereof Having Shrink Properties," the entire disclosure of which is hereby incorporated by reference. One commercially suitable heat-shrinkable suspension material is SHRINX fabric available from Krall + Roth, germany.

Referring to fig. 27, in one embodiment, the suspension material is made from a fabric blank 500, the fabric blank 500 having a plurality of heat-shrinkable elastic (elastomeric) threads 552 configured as monofilaments in one embodiment and having a plurality of non-stretchable threads 554 configured as yarns or monofilaments in a different embodiment, the heat-shrinkable elastic threads 552 extending in a first cross direction 4 or warp direction, the threads 554 extending in the same cross/warp direction 4. It should be understood that heat shrinkable elastic threads (e.g. monofilaments) and non-extensible threads (e.g. monofilaments) may also extend in the longitudinal direction 2, 2'. In one embodiment, the heat-shrinkable elastic strands 552 and the plurality of non-extensible strands 554 are arranged in a 1:1 or 2:1 alternating arrangement, or side-by-side as shown in FIG. 27, with various embodiments of knit densityThe degree is 4 to 10 elastic threads/cm, more preferably 7 to 9 elastic threads/cm, and the weaving density is 8 elastic threads/cm in one embodiment. In other embodiments, the ratio of strands may vary, with more or less elastic strands than non-extensible strands. In one embodiment, the diameter of the elastic wire is about 0.40mm, wherein it is understood that the elastic wire can be made thicker or thinner depending on the desired spring rate. It should be understood that more or fewer elastic strands may be used depending on the cross-sectional area of the strands. For example, the knit density can be defined by the total cross-sectional area of the combined elastic strands per centimeter (measured longitudinally), including, for example, a combined cross-sectional area of 0.502mm in various embodiments²Cm and 1.256mm²Between/cm, more preferably 0.879mm²A/cm and 1.130mm²A combined cross-sectional area of between/cm and in one embodiment of 1.005mm²Elastic threads of/cm (whether single or multiple threads).

In one embodiment, a plurality of yarn strands 556 are interwoven with the elastomeric strand 552 and the non-extensible strand 554 in the weft or longitudinal direction 2, 2'. The non-extensible strands 554 and yarn strands 556 do not shrink when exposed to heat or energy and are not elastomeric. Instead, the yarn strands 556 provide shape control for the entire suspended material in the final configuration after heat shrinking. The yarn strands 556 may be made of various colors, such as blue, to provide color to the textile material. Thus, the overall colour of the blank can be easily changed simply by introducing different yarns in the weft direction. In contrast, the elastomeric threads are preferably transparent or black.

Referring to fig. 26 and 29, the ring support 156 is secured to the fabric blank, such as by sewing or with staples or other fastening systems, wherein the ring support has a first annular edge 558 and a second annular edge 560. As shown in fig. 22 and 23, the annular stent is rotatable 180 degrees between a first configuration in which the first annular edge 558 is disposed radially inward of the second annular edge 560 and a second configuration in which the first annular edge 558 is disposed radially outward of the second annular edge 560. The first annular edges 558 on opposite sides of the stent define a first dimension and a second dimension in the first lateral direction 2, 2' when the stent is in the first configuration and the second configuration, wherein the first dimension and the second dimension are substantially the same in one embodiment, meaning that as the stent rotates, the first annular edges remain stationary even though the stent rotates 180 degrees. The stent 156 includes an open notch 157 in the second annular edge, the notch 157 being closed and allowing the stent to rotate from the first configuration to the second configuration. The fabric blank 500 is initially configured with pockets of additional material at the corners to accommodate rotation of the support at these corners. After rotation, the bracket 156 may be installed in the carrier frame 100, and then the carrier frame and fabric are installed or coupled to the support frame 62 with the flexible rim 162 connected to the support frame 62 and disposed around the perimeter of the textile material.

Energy, such as heat, may be applied to the fabric blank from an energy source, causing the heat-shrinkable elastomeric strands 552 to shrink. In other embodiments, the textile material is wrapped or covered over a pad or underlying substrate, such as a plastic or metal mesh supporting a user, with the edges of the textile material secured to a carrier frame as described herein. In these embodiments, textile material 150 may, but need not, be placed under tension around the pad or across opening 134.

The flexible edge member 162 is configured as a ring that surrounds and is coupled to the peripheral edge 92 of the support frame. It should be understood that the loop may be continuous or the flexible edge member may extend only partially around the perimeter of the carrier frame 100. A flexible edge member 162 extends upwardly from the support frame 64 and has an inner peripheral surface 164 or face facing inwardly toward the carrier frame's peripheral edge surface 130 and spaced from the peripheral edge surface 130 to form a gap G in communication with the groove 136, the gap G being, for example and without limitation, of a width between 0.50mm and 1.00mm, meaning that the groove and gap form a continuous but non-linear slot opening or passageway that receives the textile material 150. In one embodiment, the inner surface 164 is generally planar and has a vertical direction and extends in the Z-direction, but it should be understood that the edge surfaces 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 remains constant regardless of whether either surface or gap G is linear. In one embodiment, the gap G is the same as or slightly greater than the thickness of the textile material, which may have a thickness of about 0.75mm to 1.00mm, 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, wherein the surfaces 130, 164 abut and/or compress or slightly compress the textile material 150 between the surfaces 130, 164. Inner surface 164 faces and covers groove 136 and textile material 150. In addition, the flexible edge member 162 further grips the bracket 156 and the textile material 150, thereby further helping to ensure that the bracket 156 does not become dislodged from the groove 136.

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 so that the flexible edge member may be compressed, for example, if impacted. The flexible edge member 162 is more elastic, or more flexible, and has a significantly lower modulus of elasticity than the support frame 62, and one embodiment has a hardness in the shore D range of 80 to 90, among other hardnesses. The flexible edge member 162 protects the textile material 150 from inadvertent impact and wear, and the flexible edge member 162 has an upper surface 166 that is substantially flush with, or slightly below, the upper surface 168 of the textile material 150, thereby preventing snagging (snap) and providing a pleasing appearance. As mentioned, the flexible edge member 162 is contiguous with or slightly spaced apart from the portion of the textile material 150 disposed between the flexible edge member 162 and the carrier frame 100. The flexible edge member has a groove 170, wherein the peripheral edge 92 of the support ring is disposed in the groove 170. In one embodiment, the flexible edge member 162 is overmolded onto the support frame 62 or the peripheral edge 92 of the 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 by an adhesive, mechanical fasteners such as nails or screws, or a combination thereof. The geometry of the flexible edge member 162 further facilitates the protective and resilient properties of the flexible edge member 162. For example, the flexible edge member 162 may taper from a first thickness T1 along the inner surface 164 toward a second thickness T2 at an outermost peripheral edge of the flexible edge member 162, where the thickness is measured parallel to the inner surface 164, or in a generally Z-direction. In one embodiment, the nose tapers to a point at T2 ═ 0. In one embodiment, the cross-section of the flexible edge member 162 has a rounded nose shape. As shown in fig. 7B, the flexible edge member 162 may be compressed in response to a load applied in the X-direction and/or the Y-direction, and may also deflect in response to a load applied in the Z-direction.

In one embodiment, the auxiliary support members 200, shown as pads, are disposed between the upper surface 126 of the carrier frame 100 and the bottom surface 190 of the textile material 150 configured as a suspension material or between the space defined between the upper surface 126 and the bottom surface 190. When the suspension material is in an unloaded configuration (i.e., a user is not on the suspension material), the upper surface 202 of the auxiliary support member 200 is spaced from the bottom surface 190 of the suspension material such that a gap G2 or space is defined between the upper surface 126 and the bottom surface 190. In various embodiments, the gap G2 may be held constant with the pad having a contoured upper surface 202 that matches the contour of the bottom surface 190 of the suspended material. In various embodiments, the gap G2 is greater than 0 and less than 5mm, and in one embodiment 3mm, such that once a user engages or sits on the suspended material, the suspended material contacts the auxiliary support member 200. 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 forward to cover the opening 118 and support the user's thighs. The auxiliary support member may be made of foam. The auxiliary support member 200 may be secured to the support platform 30 and/or the carriage frame 100 with fasteners, including mechanical fasteners such as screws or adhesives. In one embodiment, the auxiliary support member 200 has a base substrate 201, such as a plastic or wood board, which base substrate 201 may be engaged with fasteners and connected to or embedded in an upper foam pad 203 as shown in fig. 20.

In operation, and with reference to fig. 18, 19 and 30, when a user sits on the suspension material 150, the load applied to the suspension material 150 causes the suspension material 150 to deflect downward toward the auxiliary support member 200. If the load causes the suspended material to deflect across the distance G2 and become in contact with the auxiliary support member 200, the auxiliary support member 200 may thereafter absorb the additional load and support the user.

It should be understood that in other embodiments, the auxiliary support member 200 abuts and supports the textile material in an unloaded state. For example, the textile material may cover only the pads that fill the spaces of the cavities 132 of the carrier frame, with the textile material forming a decorative cover on top of the pads.

In one embodiment, a method of manufacturing or assembling the 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 a peripheral groove 136, 244 formed in the peripheral edge surface 130, 246 of the frame, wherein the brace 156, 250 engages one of the grooves. When the brackets 156, 250 are rolled for insertion into the groove, the suspension material covers the portion of the peripheral rim surface 130, 246 between the groove and the upper (or front) surface 126 (i.e., the body facing first surface of the frame). The carrier frame 100, 242 is then connected to the support frame 62, 236, the support frame 62, 236 having a flexible edge member 162, 240 secured to the support frame 62, 236, such as by a support ring 48. Rather, the flexible edge member 162 may be first connected to the carrier frame 100, such as by the support ring 48, with these 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 overmolding the flexible edge member 162 onto the support frame/support ring peripheral edge 92. The flexible edge member may be secured in other ways including with an adhesive or mechanical fastener. Energy, such as thermal energy or heat applied by radiation or convection, may be applied to the suspension material 150, 234, causing the suspension material to contract and create tension in the suspension material. Energy may be applied to the suspension material before or after the carrier frame 100, 242 is secured to the support frame 62, 212. As the suspension material contracts, the suspension material is placed under tension across the opening 134 and the brackets 250, 156 are anchored in the grooves 136, 244.

A backrest assembly:

referring to fig. 1-6 and 7B, 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 relatively rigid, meaning that it does not substantially flex/bend or otherwise elastically deform during recline. The back frame 210 has a lower portion 214 connected to the rear of the tilt control assembly 18. The lower part 214 or lower support arm extends substantially horizontally in the longitudinal direction 2' along the central axis of the seating structure. The back frame 210 is pivotable rearward relative to the base 12 during recline.

A transition portion 216, which in one embodiment is curved and defines a rearwardly facing convex arcuate shape, extends rearwardly and upwardly from the lower portion 214. A pair of laterally spaced posts 218 extend upwardly from the transition portion 216. The back frame 210 also includes an upper cross member 220 that extends between and connects the upper ends of the uprights 218, wherein the cross member 220, the uprights 218, and the lower portion 214 define a central opening 220. The back support 212, otherwise referred to as a support frame, is flexible and includes flexure regions 225, 233 that allow the back support 212 to bend and deflect in response to a user reclining in the body support structure, the flexure regions 225, 233. The back support or support frame 212 includes a pair of laterally spaced apart posts 222, each having a forward facing convex arcuate portion 223 at a first location proximate a lumbar region of the back support, wherein each arcuate portion includes and defines a flex region.

The base 224 extends between and connects the posts. The back support 212 further includes a lower portion or support arm 226 extending forward from the bottom portion, wherein the support arm or lower portion is coupled to the control assembly. The upright 222 of the back support is coupled to the upright 218 of the back frame by a connector 228. The back support 212 is pivotable together with the back frame 210. In one embodiment, the uprights 218, 222 may be pivotally connected by a mechanical pivot joint, including a pivot structure such as disclosed in U.S. patent No.9,826,839, the entire disclosure of which is incorporated herein by reference.

The back support 212 includes an upper member 230 extending between and connected to the upper ends of the pair of second uprights 222, and a bottom 224 extending between and connected to the lower ends of the pair of second uprights 222. The upper member 230, the post 222, and the base 224 define a central opening 232. The suspension material 234 is stretched across the central opening 232 and secured to the back support 212 in a manner similar to a seat.

Specifically, as shown in fig. 7B, upper member 230, base 224, and the pair of second uprights 222 define a support frame 236 having a peripheral edge 238. Flexible edge member 240 is secured to the peripheral edges of upper member 230 and upright 222, or along the face of base 224. The 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, the peripheral edge surface or face 246 being horizontally oriented between the front and rear surfaces of the carrier frame, spaced from an inner surface or inwardly facing face 248 of the flexible edge member 240, and defining a space or gap G between the peripheral edge surface or face 246 and the face 248 as disclosed above with respect to the seat assembly. The groove 244 opens outwardly from the carrier frame 242 along a peripheral edge 246 of the carrier frame 242. The suspension material 234 includes at least one shelf 250, configured in one embodiment as a ring, secured along a peripheral rim portion 252 of the suspension member 250, wherein the at least one shelf is disposed in the groove 244. The bracket 250 may be held only by friction without any auxiliary support material such as an adhesive. In one embodiment, the bracket 250 directly engages one surface of the groove 244, such as the front surface, while the fabric engages the back surface. In this way, as with the seat, the bracket engages the surface of the groove 244 that is closest to the fabric-covered surface of the carrier frame. In one embodiment, stent 250 is formed as a continuous loop having a fixed length, where stent 250 is relatively inelastic and resists elongation along the length of stent 250, but stent 250 may be flexible and bendable.

In another embodiment, and with reference to fig. 24 and 25, the support frame 236 includes a posterior wall 800 defining a body-facing surface 802, an outer peripheral edge wall 804 having an outer surface 806, and an inner peripheral edge wall 808, wherein the walls 804, 808 define a forward-facing channel 810. A lip 812 or catch extends laterally inward from the outer peripheral edge wall and, together with the rear wall 800, defines a channel 816 with a rear surface of the lip defining an engagement surface 814. The 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, the insert portion 824 being defined in one embodiment by a plurality of tabs 825 spaced around the periphery of the carrier frame 820. The insertion portion 824 is received in the channel 816 and engages the engagement surface 814. The carrier frame 820 also includes upper and lower pairs of lugs 827 that align with the lugs 829 on the support frame 236, with fasteners 831 securing the lugs 827, 829 to further connect the support frame 236 and the carrier frame 820. The carrier frame 820 includes a second flange 826, the flange 826 forming an outwardly facing groove 830 with the flange 822, and the flange 826 defining an outer peripheral edge wall 827. The flange 826 extends across the channel 810 with the edge 832 positioned adjacent to the inner peripheral edge wall 808 and enclosing the channel. The tension applied by the textile material, which in one embodiment is configured as the suspension material 150, thereafter applies a moment to the carrier frame 820, causing the carrier frame 820 to bear against the bottom and engagement surfaces of the support frame. The flexible rim member 240 is coupled to the outer surface of the peripheral rim wall 804 of the support frame with the lip portion overlying the top surface of the support frame. The flexible edge member 240 has an inner surface that is spaced from and faces inwardly toward the carrier frame peripheral edge wall, wherein a gap is defined between the inner surface and the carrier frame peripheral edge wall 827. A portion of the textile material is disposed in the gap, wherein the textile material covers the peripheral edge wall 827 of the carrier frame and the body facing surface of the carrier frame. The peripheral edge of the textile material is secured to the bracket 156, with the edge portion of the textile material and the bracket being disposed in the groove 830. The carrier frame 242 may be secured to the support frame by the overlying tabs 815, 825 and fasteners 831 including mechanical fasteners and/or adhesives.

The operation is as follows:

in operation, and with reference to fig. 18, 19, 21 and 26, a user 101 may be seated 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 amount of deflection of the side portions of the support/carrier frame coupled to the suspension material, the suspension material may engage the upper surface 202 of the auxiliary support member 200 or pad 203, which thereafter assists in absorbing the load of the user. In essence, the side portions are inwardly deflectable from a first unloaded configuration to a first loaded configuration by a first amount in response to a load applied to the resilient material, and in essence define a first spring to absorb the load of the user. The elastic textile material or suspension material 150 coupled to the side portion 114 across the opening is downwardly deflectable from a second unloaded configuration to a second loaded configuration a second amount in response to a load applied to the elastic textile material or suspension material 150 and defines a second spring to absorb the load of the user. In other words, 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. When the first and second amounts of deflection or the first amount of support cause the resilient material to contact the pad, the pad disposed below the textile material engages the resilient material and provides additional support to the resilient material, which defines a third spring to absorb the load of the user. The upper surface of the pad 203 is spaced from the textile material when the side portion 114 is in the first unloaded configuration and the resilient suspension material 150 is in the second unloaded configuration. In this manner, the flexible support/carrier frame, the resilient suspension material, and the cushion provide a first amount, a second amount, and a third amount of resilient support to a user engaging and being supported by the textile material through the combined suspension material and flexible frame. It should be understood that the elastic suspension material 150 is capable of deflecting downward a first amount in response to deflection of at least one side portion 114 or both side portions, depending on the location of the load application.

The resiliency and deflection of the side portions 114 is primarily a function of the deflection of the central portion 102 and the at least one connector 80, 108 extending between the support platform 30 and the side portions 114. The connectors 80, 108 extend upwardly and outwardly from the central portion and are curved to have an upwardly facing concave surface such that the connectors 80, 108 are rigid and resist outward/downward deflection/deformation. As described above, the connectors 80, 108 include a pair of opposing side connectors that are inwardly deflectable from a first unloaded configuration to a first loaded configuration in response to a load applied to the resilient material.

The user 101 may recline with the tilt control assembly 18 moving the seat assembly 8 and/or the back assembly 6 rearward by pivoting, rotating, translating, or a combination thereof, such as by a four bar mechanism including links 8, 23, 25, and 33.

Referring to fig. 18, 19 and 21, as the seat assembly 8 reclines or reclines, 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 the rear portion of the support platform rotate or deflect downward about the flex regions relative to the front portion 123 of the seat assembly and the front portion of the support platform. 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 the flex regions 155 such that the side members 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 members 114 ', with the textile material 150 assuming a more concavely configured textile material 150' that slightly cradles and embraces the user. As the connector 108 and outer ring 104 deflect, the overall length of the outer ring 104 remains constant and does not increase. It should be understood that references to the side members 114 moving upwardly are with respect to the support platform 30, while a portion of the support platform 30 may move downwardly such that the overall or absolute movement of the side members with respect to the ground is negligible. The support ring 48 is sufficiently flexible and compliant so that the support ring 48 does not interfere with the flexing of the carrier frame 100, but rather provides a decorative tactile skin covering the bottom surface of the carrier frame. The support ring 48 may also be provided with a flex region to allow for such flexing, if desired. Due to the geometry of the seat assembly, including the configuration of the outer ring 104, the geometry of the curved connectors 108 (e.g., upwardly concave), 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 downward deformation in response to downward loads applied along the sides of the seat at the periphery of the chair.

Due to the orientation of the forward and rearward links, and the relative positions of the flexure zones 27, 53 disposed above and forward of the flexure zones 29, 31, respectively, the four-bar linkage provides a weight-activated system, meaning that the weight of the user is taken into account when reclining, as the increase in potential energy is offset by the kinetic energy required for reclining. In this way, the four-bar mechanism will provide more resistance for heavier users and automatically balance the users. As previously mentioned, the amount of recline may be limited by the recline limiter, while energy may be supplied to increase the resistance to recline the body support assembly and return the body support assembly to the upright, nominal position.

Although the present invention has been described with reference to preferred embodiments, workers 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. It is, therefore, 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.

Claims

1. A seat assembly, comprising:

a lower support platform having a first peripheral edge, an upper surface, and a lower surface;

a support ring surrounding and extending radially outward from the first peripheral edge of the lower support platform, wherein the support ring defines a second peripheral edge and includes an upper surface;

an upper shell disposed on the upper surface of the lower support platform and the upper surface of the support ring and defining a concave cavity, wherein the upper shell has a third peripheral edge defining a central opening and has an upper surface; and

a suspension material secured to the upper shell across the central opening and covering the concave cavity.

2. The seat assembly of claim 1 wherein the suspension material is coupled to the third peripheral edge of the upper shell.

3. The seat assembly of claim 2 wherein the upper shell includes a groove extending around at least a portion of the third peripheral edge, wherein the peripheral edge of the suspension material is disposed in the groove.

4. A seat assembly as set forth in claim 3 further comprising at least one bracket coupled to said peripheral edge of said suspension material, wherein said at least one bracket is disposed in said groove.

5. A seat assembly as set forth in claim 4 further comprising a flexible rim member coupled to said second peripheral edge of said support ring wherein said rim member is disposed along said third peripheral edge of said upper shell and covers said recess.

6. A seat assembly as set forth in claim 5 wherein said flexible edge member includes a second groove with said second peripheral edge of said support ring disposed in said second groove.

7. The seat assembly of claim 5 wherein an upper surface of the flexible rim member is substantially flush with an upper surface of the suspension material.

8. The seat assembly of claim 1 further comprising a gasket disposed between the upper surface of the upper shell and a bottom surface of the suspension material.

9. The seat assembly of claim 8 wherein an upper surface of the cushion is spaced apart from the bottom surface of the suspension material.

10. The seat assembly of claim 1 wherein the lower support platform has a generally trapezoidal shape with a rear edge shorter than a front edge and a pair of side edges joining the front edge and the rear edge.

11. The seat assembly of claim 1 wherein the support ring has a central opening defined by an inner peripheral edge surrounding and coupled to the rear edge, the front edge and the side edges of the lower support platform.

12. A seat assembly as set forth in claim 11 wherein said support ring comprises an inner ring and an outer ring, said inner ring having a trapezoidal shape and defining said inner peripheral edge, wherein said inner and outer rings are joined by at least two connectors.

13. A seat assembly as set forth in claim 12 wherein said upper shell includes a central portion overlying said inner ring of said support ring and said lower support platform and an outer ring overlying said outer ring of said support ring and said upper surface of said support platform, wherein said outer ring and said central portion of said upper shell are coupled with at least two connectors.

14. A seat assembly as set forth in claim 1 wherein said support platform includes a pair of laterally spaced apart pads positioned at a forward portion thereof, each of said pads including at least one first mounting member.

15. A seat assembly as set forth in claim 14 wherein said support platform includes a boss structure extending downwardly from a rear portion of said support platform, wherein said boss structure includes at least one second mounting member.

16. A seat assembly as set forth in claim 15 wherein at least one of said first and second mounting members includes a fastener opening.

17. A seat assembly as claimed in claim 45, in which the upper surface of the support platform has a concave shape.

18. A body support member comprising:

a carrier frame comprising a first body-facing surface, a second surface opposite the first surface, a peripheral rim surface extending between the first and second surfaces, and a peripheral groove formed in and opening outwardly from the peripheral rim surface;

a support frame comprising a peripheral edge;

a flexible rim member connected to the peripheral rim of the support frame, the flexible rim member having an inner surface spaced apart from and facing inwardly toward the peripheral rim surface of the carrier frame, wherein a gap is defined between the inner surface and the peripheral rim surface, wherein the gap is in communication with the peripheral groove; and

a textile material comprising a peripheral edge, wherein the textile material covers the first surface of the carrier frame and is disposed in the gap between the inner surface of the flexible rim and the peripheral edge surface of the carrier frame, wherein the textile material engages at least a portion of the peripheral edge surface of the carrier frame, and wherein the peripheral edge of the textile material is disposed in the peripheral groove of the carrier frame.

19. The body support member of claim 18, wherein the flexible edge member is made of a first material and the carrier frame is made of a second material, wherein the first material has a lower durometer than the second material.

20. The body support member of claim 19, wherein the flexible edge member has a lower modulus of elasticity than the carrier frame.

21. The body support member of claim 18, wherein the flexible edge member is overmolded on the peripheral edge of the support frame.

22. The body support member of claim 18, wherein an upper surface of the flexible edge member is substantially flush with an upper surface of the suspended material.

23. The body support member of claim 18, further comprising at least one brace coupled to the peripheral edge of the textile material, wherein the at least one brace is disposed in the peripheral groove of the carrier frame.

24. The body support member of claim 23, wherein the brace has a first side facing the first side of the textile material and a second side opposite the first side, wherein the second side of the brace directly engages a first surface that partially defines the peripheral groove in the carrier frame.

25. The body support member of claim 24, wherein the textile material has a second side opposite the first side, wherein the second side of the textile material directly engages a second surface that partially defines the peripheral groove in the carrier frame.

26. The body support member of claim 23, wherein the at least one brace is disposed in the peripheral groove without any adhesive.

27. The body support member of claim 18, wherein the first surface of the carrier frame includes a landing portion that engages the textile material and an angled portion that extends away from the textile material, wherein the angled portion is not engaged with the textile material in an unloaded configuration.

28. The body support member of claim 18, wherein the peripheral edge of the support frame extends outwardly beyond the peripheral edge of the carrier frame.

29. The body support member of claim 18, wherein the flexible rim member tapers from a first thickness adjacent the peripheral rim surface of the carrier frame to a second thickness at an outermost peripheral rim of the flexible rim member, wherein the first thickness is greater than the second thickness.

30. The body support member of claim 29, wherein the flexible edge member has a rounded nose shape.

31. The body support member of claim 18, wherein the textile material is made of a heat shrinkable material.

32. The body support member of claim 18, further comprising a pad having a support surface, wherein the textile material comprises a suspension material that is deflectable from an unloaded configuration in which the suspension material is spaced from the support surface of the pad to a loaded configuration in which the suspension material engages the pad.

33. The body support member of claim 18, wherein the carrier frame defines a central opening and a concave cavity, wherein the textile material is secured across the central opening and covers the concave cavity.

34. The body support member of claim 33, further comprising a cushion disposed in the cavity and supported by the carrier frame, wherein the cushion is spaced apart from the textile material when the textile material is in an unloaded configuration such that a gap is defined between the cushion and the textile material.

35. The body support member of claim 18, wherein the peripheral groove angles downwardly away from the peripheral rim surface, and wherein the peripheral groove and the peripheral rim surface form an angle between 45 degrees and 90 degrees.

36. A seat comprising the body support member of claim 18, wherein the peripheral edge surface of the carrier frame, the inner surface of the flexible edge member, and the gap are substantially vertical.

37. A backrest comprising the body support member of claim 18, wherein the peripheral edge surface of the carrier frame, the inner surface of the flexible edge member, and the gap are substantially horizontal.

38. A chair comprising a seat and a backrest, wherein at least one of the seat and the backrest comprises a body support member according to claim 18.

39. A method of manufacturing a body support member, the method comprising:

disposing a peripheral edge of a textile material into a groove formed in a peripheral edge surface of the carrier frame;

covering at least a portion of the peripheral edge surface of the carrier frame and a first body-facing surface of the carrier frame with the textile material; and

connecting a flexible rim member to the carrier frame, wherein the flexible rim member has an inner surface spaced from and facing inwardly toward the perimeter rim surface of the carrier frame, wherein a gap is defined between the inner surface and the perimeter rim surface, wherein the gap is in communication with the perimeter groove, and wherein the textile material is disposed in the gap.

40. The method of claim 39, further comprising applying energy to the textile material and shrinking the textile material.

41. The method of claim 39, wherein disposing the peripheral edge of the textile material into the peripheral groove comprises inserting a stent coupled to the textile material into the peripheral groove.

42. The method of claim 41, further comprising directly engaging a surface of the peripheral groove with the stent.

43. The method of claim 39, wherein connecting the flexible edge member to the carrier frame comprises connecting a support frame to the carrier frame, wherein the flexible edge member is coupled to the support frame.

44. The method of claim 43, further comprising overmolding the flexible edge member to the support frame.

45. The method of claim 39, wherein the flexible edge member is made of a first material and the carrier frame is made of a second material, wherein the first material has a lower durometer than the second material.

46. The method of claim 45, wherein the flexible edge member has a lower modulus of elasticity than the carrier frame.

47. The method of claim 42, wherein the surface of the peripheral groove comprises a first surface, and further comprising directly engaging a second surface of the groove with the textile material.

48. The method of claim 41, wherein inserting the bracket comprises inserting the bracket without an adhesive disposed in or on the groove.

49. A seat assembly, comprising:

a lower support platform extending in a longitudinal direction and comprising opposing side edges and a laterally extending first flexure region extending between the opposing side edges, wherein the first flexure region branches the lower support platform into a front portion and a rear portion, wherein the first flexure region is bendable such that the rear portion is deflectable downward relative to the front portion; and

an upper shell comprising opposing side members connected to the support platform by a pair of connectors, each of the connectors comprising a second flex region, wherein the second flex regions are bendable such that the opposing side members are movable upwardly and/or inwardly relative to the lower support platform when the rear portion is deflectable downwardly relative to the front portion.

50. A seat assembly as defined in claim 49, wherein the upper shell defines a concave cavity and includes an outer ring defining a central opening, wherein the side member at least partially defines the outer ring.

51. A seat assembly as set forth in claim 49 further comprising a suspension material secured to said outer ring of said upper shell across said central opening, wherein said suspension material covers said concave cavity.

52. A seat assembly as defined in claim 51, wherein the upper shell comprises a groove extending around at least a portion of the outer ring, wherein a peripheral edge of the suspension material is disposed in the groove.

53. A seat assembly as set forth in claim 52 further comprising at least one bracket coupled to said peripheral edge of said suspension material wherein said at least one bracket is disposed in said groove.

54. A seat assembly as set forth in claim 53 further comprising a support ring surrounding and extending radially outwardly from said lower support platform, wherein said support ring defines a second peripheral edge, and a flexible edge member coupled to said second peripheral edge of said support ring, wherein said flexible edge member is disposed along the peripheral edge of said outer ring and covers said groove.

55. A seat assembly as set forth in claim 51 further comprising a gasket disposed between an upper surface of said upper shell and a bottom surface of said suspension material.

56. A seat assembly as set forth in claim 55 wherein an upper surface of said cushion is spaced from said bottom surface of said suspension material.

57. A seat assembly as set forth in claim 49 wherein said lower support platform has a generally trapezoidal shape with a rear edge shorter than a front edge and opposite side edges joining said front and rear edges.

58. A seat assembly as set forth in claim 49 wherein said upper shell includes a central portion overlying said lower support platform and outer rings partially defining said opposing side members, wherein said outer and central portions of said upper shell are coupled with said pairs of connectors.

59. A seat assembly as set forth in claim 49 wherein said second flex region is bendable such that said opposing side members are movable inwardly toward one another when said rear portion is deflectable downwardly relative to said front portion.

60. A seat assembly as claimed in claim 58 wherein the outer ring remains fixed length when the opposing side members are movable upwardly and/or inwardly relative to the lower support platform.

61. A chair comprising any combination of the preceding claims.

62. A body support member comprising:

a carrier frame comprising a central portion and a peripheral ring connected to the central portion by a plurality of connectors, the connectors each comprising a flex region, the peripheral ring defining a central opening;

an elastic textile material coupled to the peripheral ring across the central opening; and

a pad disposed between the central portion and the textile material;

wherein at least one connector of the plurality of connectors is inwardly deflectable from a first unloaded configuration to a first loaded configuration by a first amount in response to a load applied to the resilient material, and wherein the resilient material is downwardly deflectable from a second unloaded configuration to a second loaded configuration in response to a load applied to the resilient material, and wherein the pad engages and provides additional support to the resilient material when the first amount of deflection and the second amount of deflection cause the resilient material to contact the pad.

63. The body support member of claim 62, wherein the pad includes an upper surface that is spaced apart from the textile material when the connector is in the first unloaded configuration and the elastic material is in the second unloaded configuration.

64. The body support member of claim 62, wherein the resilient material is deflectable downward a first amount in response to deflection of the at least one connector.

65. The body support member of claim 62, wherein the at least one connector extends upwardly and outwardly from the central portion.

66. The body support member of claim 65, wherein the at least one connector is curved and includes an upwardly facing concave surface.

67. The body support member of claim 62, wherein the plurality of connectors includes at least one first side connector extending laterally from a first side of the central portion and at least one second side connector extending laterally from a second side of the central portion opposite the first side, wherein each of the first and second side connectors is deflectable inwardly from the first unloaded configuration to the first loaded configuration in response to a load applied to the resilient material.

68. The body support member of claim 18, wherein the support frame includes a lip extending inwardly from the peripheral edge, and wherein the carrier frame includes an insert portion disposed below the lip of the support frame.

69. The body support member of claim 68, wherein the support frame includes a first side wall defining the peripheral edge and a bottom wall extending laterally inward from the first side wall, wherein the lip extends laterally inward from the first side wall in spaced relation to the bottom wall such that a first channel is defined between the lip and the bottom wall, wherein the insert portion is disposed in the first channel.

70. The body support member of claim 69, wherein the support frame further comprises a second sidewall extending upwardly from the bottom wall, wherein the first and second sidewalls are spaced apart, and wherein the bottom wall, the first sidewall, and the second sidewall define an upwardly open second channel.

71. The body support member of claim 70, wherein the carrier frame is disposed in the second channel.

72. A body support member comprising:

a carrier frame comprising a first body facing surface and a first peripheral edge, wherein the first peripheral edge comprises a laterally outwardly extending insertion portion;

a support frame comprising a second body facing surface and a second peripheral edge, wherein the second peripheral edge comprises a laterally inwardly extending lip, wherein the carrier frame overlies the second body facing surface, wherein the insertion portion is located below the lip; and

a textile material comprising a peripheral edge, wherein the textile material covers the first body facing surface of the carrier frame and is connected to the first peripheral edge of the carrier frame.

73. The body support member of claim 72 wherein the first peripheral edge includes a groove that opens laterally outward from the first peripheral edge, and wherein the peripheral edge of the textile material is disposed in the groove.

74. The body support member of claim 73, further comprising a flexible edge member connected to the second peripheral edge of the support frame, the flexible edge member having an inner surface spaced apart from and facing inwardly toward the first peripheral edge of the carrier frame, wherein a gap is defined between the inner surface and the first peripheral edge of the carrier frame, wherein a portion of the textile material is disposed in the gap.

75. A body support member comprising:

a carrier frame including at least opposing side portions defining an opening therebetween;

an elastic textile material coupled to the side portion across the opening; and

a pad disposed below the textile material;

wherein at least one of the side portions is inwardly deflectable from a first unloaded configuration to a first loaded configuration by a first amount in response to a load applied to the elastic material, and wherein the elastic material is downwardly deflectable from a second unloaded configuration to a second loaded configuration by a second amount in response to a load applied to the elastic material, and wherein the cushion engages and provides additional support to the elastic material when the first amount of deflection and the second amount of deflection cause the elastic material to contact the cushion.

76. The body support member of claim 75, wherein the cushion includes an upper surface that is spaced apart from the textile material when the side portions are in the first unloaded configuration and the elastic material is in the second unloaded configuration.

77. The body support member of claim 75, wherein the resilient material is deflectable downward a first amount in response to deflection of the at least one side portion.

78. A body support member comprising:

a flexible carrier frame deformable from an unloaded configuration to a loaded configuration;

an elastic textile material coupled to the carrier frame; and

a pad disposed below the textile material;

wherein the flexible carrier frame, the resilient material, and the cushion provide a first amount, a second amount, and a third amount of resilient support to a user engaging and supported by the textile material.

79. The body support member of claim 78, wherein the cushion includes an upper surface that is spaced apart from the textile material when the carrier frame is in the unloaded configuration.