Multilayer load bearing structure

Support elements and support structures form the basis of ergonomic body supports for chairs, mattresses and other structures. The support elements may be individually designed according to their location and body support function. Thus, the structures that include the support elements may provide point-tailored support for any part of the body to enhance comfort, fit, and proper anatomical support.

BACKGROUND

1. Technical Field

The present invention relates to load bearing structures. In particular, the present invention relates to multiple layer load bearing structures.

2. Background Information

People spend a significant number of hours sitting each day. Regardless of the task being performed, or the leisure activity being pursued, support structures that properly support the body not only make the individual more comfortable, but may also provide significant health benefits. For this reason, extensive research and development has occurred and continues to occur into support structures for chairs, mattresses, and so forth.

In the past, for example, bed systems have encompassed a wide range of designs, ranging from simple cushions to complex arrangements of individual bearing elements. These past designs have been successful to varying degrees, but do not always provide the appropriate level of support for each part of the body. Thus, while some progress has been made in providing ergonomic body support structures, there remains a need for improved support structures that provide excellent fit and comfort, as well as healthy support for the body, across a wide range of individual body types.

BRIEF SUMMARY

Structural components consistent with the present invention provide pixelated body support elements as well as pixelated body support structures incorporating the pixelated body support elements. The support structures may be employed in the design of a backrest or seat for a chair, as examples, or may be incorporated into any other body support device (e.g., a mattress or bed system). The pixelated support elements may be independently designed according to their selected or assigned location in the support structure. The resultant design may thereby provide point-tailored support for the body that varies according to support most beneficial or desirable for any given body region.

In one implementation, a pixelated support element for a pixelated support structure may include a spring cradle that includes a cradle base and a spring support structure. In addition, the pixelated support element includes a spring element at least partially disposed in the spring cradle. The spring cradle may then be designed to impart a selected spring stiffness to the spring element.

In another implementation, the pixelated support element may include an upper support layer defining a series of peaks and valleys and a lower base layer also defining a series of peaks and valleys. Additionally, an elastomer material is disposed between the upper support layer and the lower base layer, and imparts a selected degree of stiffness to the pixelated support element.

Similarly, a pixelated support structure consistent with the present invention may include a support spine, a spline disposed laterally across the support spine, and cantilever branches extending outwardly from the spline. Each cantilever branch may include a terminal end connected to the spline, a support end opposite the terminal end, and a load bearing element connected to the support end. Additionally, a bridging connection is provided between pixelated support elements, thereby connecting sets of load bearing elements together into larger groups (e.g., a 2×2 or 4×4 group of load bearing elements). The bridging connection between elements prevents neighboring support elements from pinching the body between them as they flex differentially.

In a similar implementation, the pixelated support structure may include a support spine, a first spline laterally disposed across the support spine, and multiple pixelated support elements connected to the spline in a longitudinal array across the spline. A wide variety of pixelated support elements may be employed. As one example, one or more of the pixelated support elements may include a spline connection, a spring arm emerging from the spline connection, and a load bearing element at the end of the spring arm.

Generally, the support spine may be curved in accordance with a selected anatomical structure. Thus, as examples, the support spine may take the form of a back rest curved spine, or a seat rest curved spine.

In addition, the support spine may be flexible lengthwise so that the support elements follow gross motions of the body. The overall support structure may then have a springing action all along its length (both cantilever and torsional), or may be hinged along its length and driven into the desired position, for example, by rigid body mechanics.

DETAILED DESCRIPTION

Before turning to a detailed discussion of the Figures, it is noted that pixelated body support generally refers to an array of individual body-support elements that in combination provide support for some or all of an individual's body. For example, the body support may include an array of closely spaced pixelated support elements that define a support surface for an individual. As will be explained in more detail below, the pixelated support elements may take many forms, including, for example a spring-loaded element formed as, or biased by, mechanical or pneumatic springs or by other devices. Furthermore, the stiffness or biasing force of the pixelated support elements may be individually designed as desired to suit the particular body support needs of the individual and the application.

Several exemplary implementations of pixelated support elements (referred to below as “elements” or “support elements”) are discussed next. Subsequently, pixelated support structures that may incorporate the pixelated support elements are presented.

With regard first toFIG. 1, that figure shows two pixelated support elements100,102. The support element100is shown in an uncompressed state, while the support element102is shown in a compressed state. Each support element100,102may be constructed in the same manner. For example, the support element100includes a spring cradle104that may generally be regarded as including a cradle base106and a spring support structure108. In addition, a spring element110is partially disposed in the spring cradle104. As shown inFIG. 1, the spring cradle104provides an open area forming a spring compression area112. The spring cradle104is attached (e.g., through adhesive bonding or mechanical linkage) to a spline114.

In this instance, the spring element110is an elastic element that is shown as roughly rectangular or block shaped. However, it is noted that any other geometric shape may be used instead, depending on the desired characteristics of the particular design. Because the spring element110is elastic, it therefore deforms as weight is applied (e.g., as element102illustrates), and recovers as the weight is removed (e.g., as element100illustrates). In one implementation, the spring element110may be a gel filled structure.

The spring compression area112is shown as an open space between the spring element110and the spring support structure108. The larger the spring compression area112, the softer the associated spring element110feels. Likewise, the smaller the spring compression area112, the stiffer the associated spring element110feels. Thus, as examples, the radius and depth of the spring cradle104may be individually designed for each spring cradle to provide a pre-selected amount of stiffness for the associated spring element110.

FIG. 2shows a top view and a side view of a second pixelated support element200. The element200includes a spring cradle202that may generally be regarded as including a cradle base204and a spring support structure206. The cradle base204attaches to the spline208. In addition, a spring element210is partially disposed in the spring cradle202. The spring element210includes four elastic spring arms212,214,216,218, although additional or fewer support arms may be used in other implementations.

At end of each spring arm212-218is an L-shaped load bearing element220,222,224,226. Other shapes are also suitable. Thus, as examples, the load bearing elements220-226may be square, rectangular, or circular.

The spring support structure206is formed as a cradle arm for each elastic spring arm212-218. The cradle arm extends along the elastic spring arms212-218, thereby imparting a pre-selected tension in the each spring arm212-218. The tension may be individually adjusted for each spring arm212-218, and individually adjusted from support element to support element by changing the materials, dimensions, or length of cradle arm extending along the elastic spring arm. The height of the cradle arm is denoted inFIG. 2as dimension A.

FIG. 3illustrates an interconnection structure for pixelated support elements. In particular,FIG. 3shows a first support element302and a second support element304. Each support element302-304may be constructed as noted above with regard toFIG. 2, as an example. However, rather than or in addition to being attached to a spline, the support elements302-304may include their own branches306.

Each branch306includes an interconnection mechanism at each end. The interconnection mechanism may include a male connector308on one end of the branch306and a mating female connector310on the opposite end of the branch306. Then support elements302-304may then be coupled together to form a linear array of elements in which the connected branches306form a spline.

FIG. 4shows another example of pixelated support elements400arranged along a spline402. The elements400are formed as a curved shell404that terminates in a spring arm406. The spring arm406may be formed as an undulating section of material that provides tension and a restorative force when a load is applied that causes a portion of the curved shell404pushes down on the spring arm406.

Turning next toFIG. 5, that figure shows a perspective view of a pixelated support element500. More specifically, the pixelated support element500includes an upper support layer502and a lower base layer504. An elastomer material506is disposed between the upper support layer502and the lower base layer504.

FIG. 6shows a side view of the pixelated support element500ofFIG. 5.FIG. 6shows that the upper support layer502includes a series of peaks602and valleys604. Similarly, the lower base layer504includes a series of peaks606and valleys608disposed such that the peaks606align with the valleys604.

The peaks602and606are characterized by a separation distance that may vary from peak to peak.FIG. 6illustrates three such separation distances in decreasing order of magnitude with reference numerals610,612, and614. Similarly,FIG. 6shows that the peaks and valleys may have independently adjustable heights and depths, as shown by reference numerals616and618. The depths and heights provide a pre-selected travel distance for the upper support layer502. As one example, the travel distance may be set to be approximately 1 inch, although longer and shorter distances may also be employed.

The elastomer material506stretches both up and down when a load is applied to the upper support layer502. The spring range provided by the elastomer material506is determined by the height of the peaks of both the upper support layer502and the lower base layer504. In one implementation, the height of the peaks and the depths of the valleys may be approximately 1 inch. The spring rate may be varied by changing the separation distance between peaks as shown inFIG. 6.

For example, when the separation distance is greater (as shown on by the separation distance610on the left side ofFIG. 6), the corresponding portion of the element500provides a softer feel. Alternatively, when the separation distance is less (as shown by the separation distances612-614on the right side ofFIG. 6), then the element500also provides a stiffer feel. As examples, the separation distances610,612, and614may be 2.0 inches, 1.625 inches, and 1.5 inches. In addition, the material or thickness of the elastomer material506may be varied at design time to impart addition or lesser stiffness in any particular area. The elastomer material506may be made from many different materials, including a polymer material such as Hytrel™ material (elasticized polyethelene), Santoprene™ material (elastomerized polypropylene), Polyisopene™ material, or a polybutadience or polyurethane material.

Thus, the element500allows the spring rate and resultant stiffness to be tailored across the element500. As a result, the element500may be made stiffer where significant pressure is exerted, and softer where less pressure is exerted (or when a softer feel is desired).

FIG. 7provides another example of a pixelated support element700. The element700includes an upper load bearing element702, a lower base element704, and a spring system between the upper load bearing element702and the lower base element704. The spring system includes a compression spring706between the upper and lower elements702-704, and an elastomeric spring708disposed below the compression spring706. The two springs706-708provide sufficient restoring force, while allowing a height reduction in which the element700functions.

The compression spring706may be a conical compression spring integrally molded to the upper load bearing element702. The elastomeric spring708may then be an elastomeric membrane retained co-axially with the compression spring706. Retention may be accomplished using the perimeter of the compression spring706, or by adding a nipple to elastomeric spring708to retain the compression spring706.

In one implementation, the compression spring706is substantially softer than the elastomeric spring708and thus compresses first. When compressed, the compression spring706may then form a conical solid plunger that engages the elastomeric spring708. The elastomeric spring708then begins to stretch in elongation.

The overall element700may provide linear spring action in two regions: first during compression of the compression spring706(and minor stretching of elastomeric spring708) and then a second, steeper spring rate as the elastomeric spring708stretches. Either spring706-708may be set to be the primary travel, or it may be evenly split between the two springs706-708.

FIG. 7shows that the upper load bearing element702may be formed into a pixelated upper load bearing element array. For example, the upper array may include the pixelated elements710,712,714,716in a 2×2 array. The lower base element704may then be formed as a pixelated lower base element array, including corresponding pixelated elements718,720,722,724. The pixelated elements710-724may individually biased by spring systems and may be interconnected with hinges, such as a living hinge, including the peak and valley shape shown inFIG. 7. AlthoughFIG. 7shows 2×2 pixelated arrays of square pixelated elements710-724, the array may be larger or smaller in any particular dimension, and may include pixelated elements that are rectangular, round, or any other shape.

FIGS. 8-10show another implementation for a pixelated support element800.FIGS. 8 and 9provide a perspective view of the element800, which includes a spline connection802, spring arms804and806, and load bearing elements808and810. The element800may be a single molded piece (e.g., of thermoplastic elastomer), or constructed from separate components secured together by fasteners. In one implementation, the load bearing elements808and810of the support element800retain horizontal orientation when loaded with a vertically downward force.

The spline connection802provides an interference fit connector that may slide onto or snap onto a generally round spline. More generally, the spline connection802provides a base connection that may be attached or adhered to an underlying support structure. In an alternate embodiment, however, the support element800may be molded as a single piece with a spline or with a spline and a spine, such as those shown below inFIGS. 16and17. As another example, the base connection802may include cross pin holes through which a securing pin may be inserted to secure the support element800to a spline (including matching cross pin holes).

The underlying support structure may be a substantially one dimensional spline, or may be a two dimensional rigid or flexible backing structure. The backing structure may take the shape, as examples, of a backrest or a seat rest for a chair, optionally ergonomically curved. Thus, the backrest may be curved to provide back support that includes lumbar support, while the seat may be curved to provide support that matches the natural curves of the buttocks and thighs.

The spring arms804and806emerge from the spline connection802to provide a pair of compression arms that extend upwardly from the spline connection802. The load bearing elements808and810are then connected to the free ends of the spring arms806and804respectively. As shown inFIGS. 8-10, the spring arms804,806are formed in an undulating or zig-zag shape to provide a biasing force.

FIG. 10provides exemplary dimensions for the element800that are particularly suitable when the element800is incorporated into a pixelated support structure in a chair.

FIG. 11depicts a support structure1100including pixelated support elements (three of which are labeled1102,1104and1106) coupled together. More specifically, each of the pixelated support elements, for example the element1102, includes a load bearing element1108, and rotational arms1110,1112, and1114. Rotational arms from sets of three neighboring pixelated support elements connect along a helix shaped path at a lower support coupling present at the end of each rotational arm. One lower support coupling is labeled1116at the end of the rotational arm1112.

Although the load bearing elements are show as circular, they may take another shape in accordance with the particular design. The helical rotational arms1110-1114, through the support couplings, allow the pixelated support elements to rotate off-center (e.g., as shown, counterclockwise) and move together when a load is applied to the load bearing elements. The load bearing elements may thus provide a shearing action that provides a pleasant feel to the body.

In general, the support structure1100may be formed through a molding process. In particular, a thermoplastic elastomer may be injected into a mold providing the load bearing element, rotational arm, and support coupling elements set forth above.

Turning briefly toFIG. 18, that Figure shows a side view1800of a portion of the support structure1100.FIG. 18shows the load bearing element1108and its three helical rotational arms1110,1112, and1114. The helical rotational arm1112is shown connected to the support coupling1116. The support couplings may be secured to a rigid base of an underlying support structure.

FIG. 12shows another example of a support structure1200including multiple pixelated support elements1202. Each support element1202includes four load bearing elements, for example, the load bearing elements1204,1206,1208, and1210. A lower base element1212is provided for each support element1202, and cantilever support arms1214,1216,1218, and1220connect the load bearing elements1204-1210to the lower base element1212. A distance R separates the lower base element1212and the load bearing elements. Material cutouts1222and1224are also shown.

The support structure1200may be formed in a manner similar to the support structure1100. For example, a mold may be formed to provide the load bearing element, base element, and support arm shapes shown inFIG. 12. A thermoplastic elastomer may then be injected into the mold to realize the support structure1200. The base elements may be secured to a rigid base of an underlying support structure.

FIG. 13shows a side view1300of a portion of the support structure1200, in an uncompressed state1302and a compressed state1304. As shown inFIG. 13, the cantilever support arms1218and1220couple load bearing elements1204and1210to a lower base element1212. The cantilever support arms1218and1220will deflect in an arc when a load is applied to the load bearing elements1204and1210. The spacing of the bearing elements equalizes as the elements are deflected downwards. The materials, dimensions, and construction of the cantilever support arms1218and1220may be independently designed and selected to impart a desired stiffness, and may, for example, provide approximately 1 inch of vertical travel and (½)*R horizontal travel under compression.

Turning briefly toFIG. 19, that Figure shows a side view1900of a portion of the support structure1200. The side view shows the state of the support structure1200in an unloaded state. More specifically,FIG. 19shows the load bearing elements1204and1210connected by the cantilever support arms1218and1220to the base element1212.

The pixelated support elements discussed above (or those of other design) may be incorporated into pixelated support structures, several examples of which are set forth below.

With regard next toFIG. 14, a pixelated support structure1400is shown. The structure1400includes splines1402,1434, and1436, cantilever branches (four of which are labeled1404,1406,1408, and1410) that extend outwardly from the spline1402, and load bearing elements (six of which are labeled1412,1414,1416,1418,1420, and1422).

FIG. 14also shows two support spines1424and1426. The spline1402is disposed laterally across the support splines1424and1426as shown. The cantilever branches1404-1410generally may be regarded as including a terminal end connected to the spline1402(or integrated with the spline1402, for example as a single injection molded piece) and a support end opposite the terminal end. One terminal end is labeled1428and one support end is labeled1430inFIG. 14.

The load bearing element1412connects to the support end of the cantilever branch1406, and the load bearing element1414connects to the support end of the cantilever branch1404. Similarly, the load bearing element1416connects to the support end of the cantilever branch1408, while the load bearing element1418connects to the support end of the cantilever branch1410.

Bridging connections may connect the individual load bearing elements. The bridging connections give surface continuity that prevents pinching of the skin. For example, as shown inFIG. 14, the bridging connection1432connects the load bearing elements1412,1414,1416, and1418at their corners. The bridging connection1432forms a junction for the four load bearing elements1412-1418. In other words, sequences of four load bearing elements are connected together (e.g., at their corners) to form 2×2 pixelated groups that extend in a linear array laterally across the spline1402. In other implementations, the groups may be larger than a 2×2 group or smaller than a 2×2 group. The load bearing elements1412-1418are otherwise disconnected from one another, and thereby provide an independent pixel support for the body part at rest on the particular load bearing element.

The spines1424and1426may support additional splines disposed from one another and constructed as noted above, including as examples the splines1434and1436. Thus, the load bearing elements not only extend laterally across the splines, but also longitudinally along the spines1424and1426. When bridging connections are added to couple together sets of four load bearing elements, a two dimensional pixelated mat of load bearing elements is formed and supported by the spines1424-1426. Each of the cantilever branches may be independently designed by selection, dimension, and composition of materials and dimensioning to provide a pre-selected stiffness, adjusted, for example, according to the body part supported by the load bearing element attached to the cantilever branch.

The spines1424-1426may be curved to accommodate a selected anatomical structure. For example, inFIG. 14, the spines1424-1426are curved to form an ergonomic seat rest. As another example, the spines1424-1426may also be curved to form a back rest, including lumbar support.

FIG. 15depicts an alternate implementation of a pixelated support structure1500similar to that shown inFIG. 14. InFIG. 15, a spine1502supports five splines1504,1506,1508,1510, and1512disposed laterally across the spine1502. Each spline includes one or more cantilever branches to either side of the spine1502. Several of the cantilever branches for the spline1504are labeled1514,1516,1518, and1520.

Although not illustrated inFIG. 15, one or more of the cantilever branches may support a load bearing element as illustrated above inFIG. 14. Additionally, the load bearing elements may be connected via bridging connections to form pixel groups of multiple bearing elements. As shown above inFIG. 14, the bridged load bearing elements may then form a one dimensional array laterally across a given cantilever branch, or a two dimensional array extending across multiple cantilever branches.

Turning next toFIG. 16, a pixelated support structure1600includes a spine1602and one or more perpendicularly crossing splines (two adjacent splines are labeled1604and1606). Each spline1604,1606will carry one or more pixelated support elements to form a one dimensional array of support elements laterally across a given spline. When multiple adjacent splines carry the pixelated support elements, the elements may then form a two dimensional array extending along the spine1604in one dimension and along the spines1604-1606in a second dimension.

As shown inFIG. 16, the spine1602is curved to form a back rest, including lumbar support. Note also that a similar spine1608and crossing splines (e.g., the spline1610) may also be provided to form an ergonomically curved seat rest. The splines1604,1606, and1610, in one implementation, may have a substantially round cross section. The splines1604,1606,1610may also be curved (e.g., initially away from the spines1602,1608) to form a curvature, depression or other shape for supporting the back or buttocks. Suitable construction materials include glass filled nylon, polycarbonates, Polyethylene Terephthalate (PET) plastics, and the like.

One or more sections of the spines may be implemented using a flexible material. Thus, for example, the spine1602may include an upper spine section1612and a lower spine section1614that may flex either by chair kinematics or user movement. The upper spine section1612and the lower spine section1614may be joined at an inflection point1616that may be a floating inflection point, for example. The inflection point may be implemented using a pin, hinge, or other coupling structure. In this manner, for example, the support structure1600may act as an analog of the human spine, in that the spine section1612will flex together with the human spine (e.g., as the user reclines).

In one implementation, the upper spine section1612flexes backwards while the lower spine section1614flexes forward. To this end, the upper spine section1612may, for example, be sprung forward with a cable and spring assembly that can be overcome by pushing back against the upper spine section1612. Thus, instead of the support spine1602being a relatively rigid structure, the support spine1602may instead flex along one or more sections. As shown inFIG. 16, for example, the lower spine section1614flexes inward to support the lower back, and the upper spine section1612flexes backwards. The spine1602, splines, and support elements may be formed individually or in combination as a single molded piece.

FIG. 17shows another view of a pixelated support structure1700similar to that shown inFIG. 16, but including pixelated support elements. InFIG. 17, splines laterally cross supporting spines (occluded in this view). As with the implementation shown inFIG. 16, the spines may be constructed as one or more sections of flexible spine sections to provide, for example, a flexible support for the upper and lower back. For example, the spline1702extends across a back rest spine near the top of the back rest spine. The spline1702carries multiple pixel support elements1704. Five of the support elements1704are shown in position across the innermost portion of the spline1702, including a first support element1706and a fifth element1708.

The pixel support elements1704may be selected from any of the pixel support elements described above. For example, the pixel support elements shown inFIGS. 8,9, and10may be connected to (or integrally molded with) the splines through their spline connection802.

Note that each support element1704may then include spring arms804and806, and load bearing elements808and810at the end of the spring arms804and806. As noted above, each support spring arm804and806may then be independently designed to provide a pre-selected stiffness. In that manner, each support element1704may provide a different level of resistance and support to provide an enhanced ergonomic and comfortable body support.

Many different spring designs may be employed to form a pixelated support element. One example is shown inFIG. 20, which shows an interconnected spring system2000that includes multiple interlinked springs2002,2004,2006, and2008. The spring system2000includes an initial termination2010, which winds into a first spring coil2012(as shown, including two turns). The first spring coil2012continues through a relatively straight connector2014through a neighboring spring interlinking point2016and into a second spring2018(as shown, also including two turns). The spring system2000continues across the springs2004,2006, and2008until it reaches the final termination2020.

The spring system2000may be implemented, for example, using Dux® D-springs available from Dux company of Sweden as part of the Dux Pascal™ spring system. The Pascal™ spring system is a cassette system, in which each cassette includes a continuous wire spring inside of tube pockets with a fabric mesh outer layer or shell. The cassettes may be ordered by specifying wire diameter and size. The size may include the number of springs along in one dimension and the number of rows of springs along a second dimension.

Cassettes of different specifications may be employed as desired across a pixelated support structure to tailor support for any part of the body. Thus, for example, stiffer cassettes may be employed where additional support is desired, while softer cassettes may be employed where less support is needed.

As one example, the pixelated support elements may be designed to give approximately 5 pounds of force at a one inch deflection (per support element). That amount of force may be independently chosen according to the individuals who will use the support structures. For example, taking a hypothetical male weighing 250 lbs, that individual has a median distribution approximated by 5 lbs/4 sq. inches (the area of a 2×2 inch pixel) in the neutral seated position. The values may increase to 9 lbs/4 sq. inches in some areas, and drop to zero around the periphery of the pixel.

Table 1, below, depicts an array of 2″×2″ support elements supporting the hypothetical individual noted above and were obtained through pressure mapping. The value in each cell is the load carried by that area, with the front of the seat horizontally at the bottom of the table (left to right), and with the centerline of the seat vertically along the table (bottom to top).

The pressure map shown in Table 1 may thus help indicate the particular support element stiffnesses desired at any given point, or for any given part of the body.

FIG. 21shows a support diagram2100of the human body that indicates exemplary locations where additional support may be provided by pixelated support elements. For example, the support elements may be tailored to provide additional support for the cranial cap2102or along all or some of the cervical spine2104. Similarly, the latissimus dorsi muscles2106, lumbar/sacrum area2108and ischia (the sit bones)2110may be targeted for additional support. Other areas that may receive support include the hind leg2112, feet2114, and arms2116between the wrist and elbow.

The spring rate of the support elements may be individually set for any of the locations. Thus, firmer support may start at higher load areas, with the support optionally feathering out as the support surface extends away. For example, firm support may be provided along the spine2104, and softened laterally away form the spine2104.

Addition examples of pixelated support elements and their implementations are discussed below. For example, with regard toFIG. 22, a support element2200is shown in a bottom view2202and a top view2204. The support element2200represents a cutaway section of a continuous surface. The support element2200includes a porous or textured layer2206formed, as examples from foam or a soft composite material. The textured layer2206provides the primary interface between the sitter and the suspension elements2208.

The suspension elements2208may be implemented as springs that rest in a cup2210. The springs may be steel springs, thereby providing a wide range of spring rate tuning capability. The cups2210provide an intermediate transition between the soft textured layer2206and the springs and a relatively rigid bottom structural surface2212. Note that the textured surface2206may be relieved to enhance air flow and reduce heat buildup.

FIG. 23presents a support element2300that is a variation on the pixelated support element800shown inFIG. 8. Specifically, the support element2300includes cutouts2302,2304,2306, and2308in the load bearing elements808and810. The cutouts2302-2308may optionally be included to provide a porous surface that enhances aeration through the textile material interface support on the load bearing elements808and810.

FIGS. 24 and 25present pixelated support structures2400and2500that are a variation on the pixelated support structures1400shown inFIG. 14. In particular, rather than connecting the load bearing elements with bridging connections, the load bearing elements are independent. As examples, the seat rest support elements2402,2404, and2406are not connected by bridging connections. Similarly, the back rest support elements2502,2504, and2506project up from their support spline without interconnection between other support elements.

The interface between the sitter and the support elements (e.g., a soft foam or fabric support) may be made thicker to mask the independent support elements. As noted above, each cantilever branch may be individually tuned to provide selected stiffness. As a result, the seat rest or back rest may provide stiffer or softer support for the body at selected locations.

Turning next toFIG. 26, that figure presents a section2600of support elements2602arranged along a central spine2604. Each support element2602includes two cantilever sections2606and2608. Each cantilever section2606includes a load bearing element2610and two spring arms2612and2614.

The spring arms2612and2614form a spring that collapses upon itself. The support elements2602may, for example, be attached to the spines that form the back rest or seat rest shown inFIGS. 14-17,24, or25instead of the cantilevered support elements. The support elements2602may be manufactured from Hytrel™ material in an injection molding process. In one implementation, there is approximately 2.0 inches between load bearing element centers, and approximately 1.5-2.0 inches vertically from the spine2604to the load bearing elements2610.

FIG. 27shows a support element2700that is a variation of the double action spring pixelated support element700. More specifically, the support element2700includes an upper load bearing element2702, a lower base element2704, and a spring system2706between the upper load bearing element2702and the lower base element2704.

The spring system2706includes the cantilever elements2708made of a flexible material. The cantilever elements2708flex downwardly to resist the action of the plunger elements2710that extend downward from the upper load bearing element2702. In particular, the cantilever elements2708, arranged conically, invert to constantly resist the plunging action of the plunger elements2710.

The lower base element2704and cantilever elements2708may be formed from an elastomer, such as Hytrel™ material, while the upper support element2702may be, for example, polypropylene. A co-molding process may be employed to form the lower base element2704to integrate the cantilever elements2708into the more rigid lower base element2704.

In addition, the V-slots2712may be included to provide a living hinge between individual lower base elements. Optionally, the intersection of each set of four support elements is left open. As a result, the plunger elements2710may articulate to some degree.

Turning toFIG. 28, that figure shows a support element2800fabricated from parallel wires2802(e.g., steel wire) and mesh2804attached between the wires2802. The support element2800may, as shown, be formed into an undulating shape that provides spring action for compression and restoration. The mesh2804may be a three dimensional knitted material

In one implementation, the mesh2804is a ‘3 mesh’ manufactured by Muller Textil of Woonsocket, R.I., USA. The mesh2804may provide the interface between the sitter and the support element2800as a whole.

FIG. 29also shows a support element2900fabricated from mesh2902and spring action filaments2904. The support element2900is formed in a tapered cylindrical shape, though other shapes may also be employed. The top of the truncated tapered cylinder forms a load bearing element. The mesh2902may be implemented in the same way as noted above with regard to the support element2800shown inFIG. 28.

The filaments2904may be nylon filaments woven by hand into the wall of the mesh2902. The filaments impart a spring effect to the mesh2902and thereby provide a restorative force as the mesh2902deforms when a load is applied to the load bearing element. In general, either of the support elements2800or2900may, be characterized by a distance of approximately 2.0 inches between load bearing element centers, and approximately 1.5-2.0 inches of vertical travel.

FIG. 30shows a section3000of support elements3002connected at bridging connections3004(e.g., a hinge) between load bearing elements3006. The load bearing elements3006are present at the end of spring arms3008. The support elements3002may be, for example, the support elements illustrated above inFIG. 8or23.

When the support elements3002are connected as shown inFIG. 30, the section3000imparts a degree of control over the load bearing elements3006. In other words, the bridging connections3004may constrain movement of the load bearing elements3006so that they do not catch or pinch the sitter.

The section3000may be extruded as a single piece. Individual sections may then be cut apart in desired lengths to be attached, as examples, to the back rest or seat rest spines shown inFIGS. 14-17and24-25. The sections may be attached by employing a mechanical means of snapping or dovetailing the sections3000onto the spines. When the wall thickness of the spring arms3008is held approximately constant, extruding multiple support elements3002in a section3000may yield a consistent spring rate among multiple support elements3002. On the other hand, when the wall thickness of the spring arms3008is varied, the spring rate may be changed. For example, the spring arms3008for the central support elements3002may be made thicker to increase the spring rate for those support elements3002, and thereby provide additional support.

FIG. 31shows a view of a multi-tier pixelated support structure3100. The structure3100includes a first tier3102, a second tier3104and a third tier3106. The third tier3106supports load bearing elements3108that may vary in shape and size. Although sixteen (16) load bearing elements3108are shown inFIG. 31, the structure3100may include more or fewer load bearing elements. The structure3100may couple tiers3102-3106together through hinges such as hinges3110,3112, and3114as examples.

Each hinge may be formed from cantilevers or living hinges. For example, the hinge3112includes a first H-shaped cantilever3116and a second perpendicularly oriented H-shaped cantilever3118. Accordingly, the tiers and load bearing elements may support loads by bending in two independent directions.

The hinges may be manufactured from polypropylene, for example. The structure3100may be formed in individual pieces for the load bearing elements, hinges, and tiers. The pieces may then be snapped or otherwise secured together to form the overall structure3100.

The first tier3102may provide a connection mechanism to an underlying support structure to which the structure3100will attach. The connection mechanism may be a snap-on interface, bolt or screw holes, or any other type of connection mechanism. Multiple structures3100may be attached to the underlying support structure to form a larger pixelated support surface for the back, seat, arms, or other area of the body.

The size of the load bearing elements3108, the size of the cantilevers, and the materials that form the structure3100may be independently adjusted to tailor the support provided by the load bearing elements. For example, a back rest incorporating the structure3100may adjust the size of the load bearing elements3108to increase support closer toward the spine and down the back.

FIGS. 32 and 33show additional views of the multi-tier pixelated support structure shown inFIG. 31.FIG. 32shows the structure3100from the bottom.FIG. 33illustrates a side view of the structure3100. The second tier3106may include four sub-tiers, three of which are visible inFIG. 32as sub-tiers3202,3204, and3206. Each sub-tier may connect to the first tier3102through H-shaped cantilevers oriented at 90 degrees to one another.

FIG. 34shows exemplary dimensional information for the multi-tier pixelated support structure3100. The structure3100may vary widely in size and shape to suit any particular design. Thus, any of the load bearing elements3108, tiers3102-3108, and H-shaped cantilevers may be independently sized and shaped. In the example shown inFIG. 34, the structure3100includes sixteen (16) load bearing elements that vary in length and width. The structure is approximately 8.750 inches wide, 4.950 inches long, and 2.120 inches high.

FIG. 35shows a view of another implementation of a multi-tier pixelated support structure3500. The structure3500includes a first tier3502, a second tier3504and a third tier3506. The third tier3506supports load bearing elements3508that may vary in shape and size and that may be connected by bridges3510. The structure3500may support sixteen (16) load bearing elements, for example, although the structure may instead support more or fewer load bearing elements.

The first tier3502may be formed as a spherical molded socket3512. A corresponding spherical ball section3514of the second tier3504couples into the socket3512as described in more detail below. The spherical socket3512has a center point3516near the contact surfaces of the load bearing elements3508. Accordingly, as the second tier3504moves, the load bearing elements3508move vertically around point3516and uncomfortable horizontal shifting may be reduced.

Similarly, the second tier3504may include molded spherical sockets3518. The third tier3506may then include a molded spherical ball section3520that couples into the socket3518. As shown inFIG. 35, the socket3518has a center point3522that may be near the contact surfaces of the load bearing elements3508. As the ball section3520moves, the load bearing elements3508move vertically around point3522. As will be shown in more detail below, the load bearing elements3508may also connect to the third tier3506through a ball and socket connection3524.

The horizontal spacing of the components of the structure3500may be from any given center point may be independently adjusted. For Example, the ball section3520may be located more closely to the center point3516than the ball section3526. In that case, the load bearing elements supported by the portion of the second tier that includes the ball section3520provide the feeling of additional force or pressure with respect to rotation around the center point3516. Similarly, because the load bearing element3528is farther than the load bearing element3530from the center point3532, the load bearing element3528has less force or pressure with respect to rotation around the center point3532. The other multi-tiered pixelated support structures may also vary the relative locations of pivots between tiers in order to configure the force applied to each load bearing element.

InFIG. 36, a sectional view of the structure3500is present. The socket3512in the first tier3502couples to the ball section3514through a bearing3602. The bearing3602may extend up through a slot3604in the ball section3514and down through a perpendicular slot3606through the socket3512. Ribs3618may be included to strengthen the ball section3514.

Each slot permits motion of the second tier3504along its length, although stops may be inserted to constrain that motion in some implementations. In addition, a friction mechanism such as a rubber O-ring may be placed between the ball section3514and the socket3512to provide resistance to gravitational or other forces that would deflect the structure when no load is applied. The bearing tabs3608,3610may snap through the slots3604,3606to retain the bearing3602in place. The third tier3506may couple to the second tier3504through the same bearing and slot arrangement.

A sectional view of the socket connection3524is also shown inFIG. 36. The socket connection3524includes a stem3612that terminates in a ball3614. The load bearing element may then include a socket3616that mates with the ball3614. The socket connection3524may permit the load bearing elements3508significant freedom of motion to comfortably support or conform to a load.

FIG. 37illustrates a bottom view of the multi-tier pixelated support structure shown inFIG. 35. The bottom view shows the slot3606through the socket3512and the bearing tabs3610that extend down through the slot3606. In addition,FIG. 37illustrates the slots3702,3704, and3706in sockets3708,3710, and3712provided in the second tier3504. Tabs3714for a spherical bearing that couples a portion of the third tier3506to the second tier3504are also shown.

The load bearing elements3508may be formed from polypropylene, for example. Rigid nylon may be used to form the tiers3502-3506. The bearing pieces may be formed from Acetal material or another self lubricating material.

FIG. 38shows exemplary dimensional information for the multi-tier pixelated support structure3500. The structure3500may vary widely in size and shape to suit any particular design. The tiers3502-3506, load bearing elements3508, ball and socket joints, and bearings may be independently sized and shaped. In the example shown inFIG. 38, the structure3500includes sixteen (16) load bearing elements3508. The structure is approximately 11.000 inches wide, 7.180 inches long, and 2.972 inches high.

FIG. 39shows a side view of a multi-tier pixelated support structure3900. The structure3900includes a first tier3902, a second tier3904and a third tier3906. The third tier3906supports load bearing elements3908. The load bearing elements3908may vary in shape, size, and number. Four load bearing elements, one supported by each of the four support arms in the third tier3906are labeled3922,3924,3926, and3928.

The structure3900may couple together the tiers3902-3906using living hinges (three of which are identified as3910,3912, and3914inFIG. 39) or in another manner. Support arms may branch out from each hinge. For example, the first support arm3916and the second support arm3918branch out from the hinge3910. Alternatively, the support arms may be elastic and deflect under dynamic load.

The structure3900may also include a base connection3920. The base connection3920may connect the structure3900to an underlying support structure. The underlying support structure may define the skeleton for a chair or any other support structure. The base connection3920may include a snap-on interface, bolt or screw holes, or other type of connection mechanism. One or more structures3900may be attached to the underlying support structure to form a larger pixelated support surface for the back, seat, arms, or other area of the body.

The structure3900may be formed from injection molded polypropylene. Injection molding may be employed for individual pieces of the structure3900, including the load bearing elements3908, tiers3902-3906, and support arms3916-3918, or for the structure3900as a whole. Individual pieces may then be snapped, screwed, glued, or otherwise secured together to form the structure3900.

InFIG. 40, a top view4000of the structure3900is present. One or more of the load bearing elements3922-3928may include a shaped edge4010. For example, the shaped edge may be scalloped to reduce the amount of straight edges between neighboring load bearing elements. The shaped edges4010may thereby reduce pinching of clothing or skin between the load bearing elements3922-3928as they move in response to an applied load.FIG. 41provides a perspective view from the back of the multi-tier pixelated support structure3900.

The structure3900may vary widely in shape and size. In one implementation where the structure3900is used to support part of a body, the structure3900may be 10.5 inches tall, and may vary between 6 inches and 9.5 inches wide. Other dimensions may be employed, and each load bearing element3922-3928may individually vary in size, shape, dimension, and material. In addition, the structure3900may include more or fewer tiers.

FIG. 42shows a side view of a multi-tier pixelated support structure4200. The support structure4200includes a first tier4202, a second tier4204and a third tier4206. Each tier may include support elements. InFIG. 42, the first tier4202includes a first tier support element4208and the second tier4204includes the second tier support elements4210and4212. The third tier4206may include one or more load bearing elements4214.

The first tier4202may include curvature in one or more planes on one or more surfaces. InFIG. 42, the first tier4202is curved in two planes on the lower surface4216that contacts the underlying support structure4217. The curvature may vary and may provide additional force or pressure at selected locations over the structure4200.

For example, inFIG. 42, the curvature of the first tier4202varies in two directions from the center point4218. The center point4218may be the tangent point between the first tier4202and the underlying support structure4217when the support structure4200is unloaded. Center points4220and4222are also shown for the support elements4210and4212.

To the left of the center point4218, the first tier4202may have a first radius, while to the right of the center point4218, the first tier4202may have a second radius. In addition, the distance between center points4218-4222may vary. InFIG. 42, the distance between the center points4218and4220is shorter than the distance between the center points4218and4222. Additional force or pressure may be given by increasing or decreasing the distance between center points, or increasing or decreasing the radius of curvature, or both.

The lower surface4216may include pegs4224that interface with receptacles4226in the underlying support structure4208. In one implementation, the underlying support structure4217may be peg board or another perforated or dimpled structure that may accept the pegs4224. The pegs4224may be sized accordingly and in one implementation may be 0.25 inches in diameter and 0.25 inches tall.

The first tier support element4208may also include receptacles that interface with pegs4228on the second tier support elements4210,4212. The load bearing elements4214may be secured to the second tier support elements4210using a fastener, snap fit, or other securing mechanism. The load bearing elements4214may be elastic or springy to add cushioning during dynamic loads. Alternatively, the elements4214may be implemented as an additional set of curved rolling surfaces. An elastic band may secure the second tier support element4210or4212to the first tier support element4208. Similarly, an elastic band may secure the first tier support element4208to the underlying support structure4217.

FIG. 43shows a top perspective view4300of the support structure4200. The support structure4200and its constituent parts may vary widely in size, shape, and material. The structure4200may be formed from injection molded polypropylene. In one implementation, the support structure4200may be approximately 2 inches tall. The first tier4202may be approximately 1 inch thick, the second tier4204may be approximately 0.5 inches thick, and the third tier4206may be approximately 0.5 inches thick.

The first tier support element4208may approximately be 8 inches wide and 8 inches long, the second tier support elements may approximately be 4 inches wide and 4 inches long, and the load bearing elements4214may be 2 inches wide and 2 inches long. InFIG. 43, the support structure is shown to accommodate one first tier support element4208supporting four second tier support elements supporting sixteen load bearing elements4214. Any other number of tiers, support elements, and load bearing elements may be employed.

FIG. 44shows a top view of a torsional pixelated support structure4400. As shown, the structure4400includes four rows4402,4404,4406, and4408and four columns4410,4412,4414, and4416of load bearing elements, such as the load bearing elements4404and4406. The structure4400may include more or fewer rows4402-4408and columns4410-4416. In one implementation, the structure may be formed from injected molded polypropylene.

The structure4400may vary widely in size. In one implementation the structure4400may be approximately 12.5 inches wide and approximately 11 inches long. The structure4400may be sized and curved as noted below to cradle, conform to, or otherwise accommodate any body part, including the spine, arms, legs, or any other part.

The structure4400shown inFIG. 44includes 16 sets of load bearing elements that may be located at intersections of the rows4402-4408and columns4410-4416. Each set may include one or more interconnected load bearing elements. As shown inFIG. 44, each set may be formed as a pair of load bearing elements, such as the element pairs4418and4420. Each element pair may include a first load bearing element and a second load bearing element connected by a bar or beam or other section of material. The load bearing elements and connecting bar for the element pair4418are labeled4422,4424, and4426, while the load bearing elements and connecting bar for the element pair4420are labeled4428,4430, and4432.

Load bearing elements, or sets of load bearing elements, may twist or otherwise deflect around a connecting bar. The connecting bar may operate as a torsional spring. For example, the load bearing elements4428and4430may twist in the same or opposite direction around the connecting bar4432.

The length of each load bearing element may be individually adjusted. Each length may be selected to set the force and pressure at any particular load bearing element or set of load bearing elements. As load bearing elements increase in size, the force and pressure decreases and as the load bearing elements decrease in size, the force and pressure increases.

For example, as shown inFIG. 44, the load bearing elements4428and4430may be smaller than the load bearing elements4460and4462. The load bearing elements4428and4430may then provide additional force and pressure with respect to the load bearing elements4460and4462. As a set, the load bearing elements4428and4430may twist in one direction (e.g., into or out of the page), with the set of load bearing elements4460and4462twisting in the opposite direction due to the coupling provided by the connecting bar4464.

The sets of load bearing elements4428and4430, and4460and4462twist around a pivot point4466where the connecting bar4464couples to the connecting bar4468. The connecting bar4468provides a fulcrum connection to the connecting bar4466. The force and pressure provided by the load bearing elements may be tailored to provide selected support for any body part, or according to other criteria.

As another example, a set of two pairs of load bearing elements is labeled4434inFIG. 44. In the set4434, the element pair4418is connected to an adjacent element pair4435by a connecting bar4436. The connecting bar4436may connect between the two connecting bars4426,4438that couple together the individual load bearing elements. The sets of load bearing elements4418,4435may twist or otherwise deflect around the connecting bar4442, which provides a fulcrum connection to the connecting bar4436.

Similarly, multiple sets of load bearing element sets may connect together through a connecting bar. The set4434connects to the adjacent set4440through the connecting bar4442. The connecting bar4442for the larger set of four load bearing element sets may connect between the connecting bar4436and the connecting bar4444for the next smaller sets of two load bearing element sets. Each set4434,4440may then twist or otherwise deflect around the connecting bar4442.

Load bearing elements may be grouped together and interconnected in incrementally larger sets. For example,FIG. 44shows a first group4446of four sets of load bearing elements coupled together to an adjacent group4448of four sets of load bearing elements through a connecting bar4450. The connecting bar4450may connect between the connecting bars4452and4454for the smaller sets of four load bearing elements. Similarly, the connecting bar4456may then connect adjacent groups of eight sets of load bearing elements by coupling between the connecting bars4450and4458.

A bottom view of the structure4400is present inFIG. 45. The bottom view shows the structure4400curved in two planes. The curvature may match the curvature of the back, legs, or another body part. The curvature in any plane is optional.

The connecting bars may perpendicularly connect between other connecting bars, or may connect at other angles. Each connecting bar may flex as well as twist to enhance spring action. Each connecting bar may also vary in depth or width to increase its stiffness. As the connecting bars couple together increasing numbers of load bearing elements, each connecting bar may also increase in size to accommodate the increasing load. For example, the connecting bars between individual load bearing elements (e.g., connecting bar4426) may be the shallowest, while connecting bars between sets of eight sets of load bearing elements (e.g., connecting bar4456) may be the deepest.

Securing tabs4502and4504may be added to a connecting bar. Screws or other fasteners may pass through the securing tabs4502and4504to secure the structure4400to an underlying frame or spine. Alternatively, the securing tabs4502and4504may snap-fit into a mating connector on the frame or spine. The structure4400may couple to the frame or spine in other manners at other points, however.

The connecting bars may vary in size and thickness. The thickness may vary according to the load borne by any given portion of the connecting bar. As an example,FIG. 45shows that the connecting bar4454includes a left branch4506and a right branch4508. The left and right branches4506,4508increase in thickness as they near the connecting bar4450where greater loads are expected. The left and right branches4506,4508decrease in thickness away from the connecting bar4450toward the individual load bearing element pairs4512,4514,4516, and4518where relatively lighter loads are present.

FIG. 49shows that a connecting bar (e.g., the connecting bar4456) in the support structure4400may run along a supporting surface4902at a contact point4904. The supporting surface4902may be part of an underlying support structure defining a chair or other object. The connecting bar and/or the supporting surface may be flat, curved, or may have other shapes. For example, the connecting bar may have a selected radius (e.g., 3 inches), and the supporting may have a larger (e.g., 4 inches) or smaller radius. As another example, the connecting bar may be flat, and the supporting surface may be curved in a convex or concave manner.

The contact point4904moves along the supporting surface4902in accordance with the position of the load on the structure4400. For example, as the load on the structure4400shifts left, the contact point4904may shift left. The curvature or lack of curvature in the connecting bar and/or the supporting surface may be selected to establish a force vector through the contact point in a given direction. In the context of a seat, for example, the force vector may be selected so that the occupant is pushed back into the chair when the occupant load is at any given position in the structure4400. Alternatively, the force vector may be selected so that the occupant is pushed out of the chair when the occupant load moves far enough forward along the structure4400.

Returning again toFIG. 44, the face of one or more load bearing elements may be contoured. In other words, the interface between a load bearing element and the skin may be selected to impart any desired feel to the load bearing elements. In addition, the connection bars shown in the structure4400may take other forms, for example a form that permits the load bearing elements or sets of load bearing elements to translate.

FIG. 50shows a torsional support structure5000that employs a translational coupling5002that may be employed between load bearing elements5004and5006. The translational coupling5002may include spring elements5008and5010. The spring elements5008and5010may include an undulating shape (such as the U-shape shown inFIG. 50) that permits the load bearing elements5004and5006to translate in the direction shown by the arrows5012and5014. The translational coupling5002is not limited to any particular shape or form, however, and may be implemented in other manners.

Through the translational coupling5002, the load bearing elements may move in the plane of the skin. Accordingly, as the skin is stretched or compressed (e.g., when the lumbar spine is flexed) the load bearing elements may move without shearing on the skin.FIG. 51shows a perspective view of the torsional support structure5000and translational coupling5004.

InFIG. 46, a side view of a multi-bar tiered pixelated support structure4600is present. The structure4600may include two columns of four load bearing elements. For of the load bearing elements are shown and are labeled4602,4604,4606, and4608. Three tiers4610,4612, and4614may support the load bearing elements. The structure4600may be made of polypropylene in an injection molding process.

A portion4616of the structure4600may couple to an underlying frame or other structural member through bolts, screws, or other fasteners, through a snap-fit, or in other ways. The structural member may be a portion of a chair frame corresponding to the lower back, for example. The load bearing elements4602-4608may then support the lower back as described in more detail below. In general, it is noted that more or fewer load bearing elements and/or tiers may be employed, and that the structure4600may be tailored to match any body part by individually adjusting the size, shape, or stiffness of the structure's components.

The tiers4610-4614may include one or more four bar connections. In the tier4610, four sets of four bar connections are present. In the first set, the living hinges4618and4620emerge as individual members from the first tier base4626. Each living hinge may include two narrowed portions that operate as hinge points. The hinge points for the living hinge4618are labeled4660and4662. Similarly, the second set of 4-bar connections includes the hinge points around the living hinges4622and4624. The third and fourth sets of four bar connections emerge from the first tier base4636. The third and fourth sets are formed by the living hinges4628,4630,4632, and4634.

In the second tier4612, the living hinges4638,4640,4642, and4644emerge from the second tier base4646. The living hinges4638and4640implement a four bar connection to the first tier base4626, and the living hinges4642and4644implement a four bar connection to the first tier base4636. Similarly, in the third tier4614, the two living hinges4648and4650emerge from the third tier base4652and implement a four bar connection to the second tier base4646.

In the third tier4610, the living hinges may branch into one or more support fingers connected to load bearing elements. For example, the living hinge4618branches out into the first support finger4656and the second support finger4658.

FIG. 46shows that the bases4626,4636, and4646may be formed in a V-shape. The V-shape occupies less space than a straight connection and may contribute to the compactness of the structure4600. In one implementation for a lumbar support, the structure4600may be approximately 10 inches wide and approximately 6 inches tell. The load bearing elements may be approximately 4.5 inches wide and approximately 1.3 inches tall. The total thickness of the support structure4600, excluding the load bearing elements4602-4608and base4616may be approximately 3.2 inches. In one implementation, they may be 0.030″ thick and may narrow down at either end, but may vary widely depending on the implementation.

The living hinges may be individually oriented to impart selected rotational characteristics to the load bearing elements4602,4604,4606, and4608. As one example, the living hinges4642and4636are angled to set a center of rotation4654for the load bearing elements4606and4608. For lumbar support, the centers of rotation may be set at any distance at or above the surface of the load bearing elements. In particular, the centers of rotation may be selected such that the load bearing elements4606and4608move with the skin, rather than along the skin.

FIG. 47shows a perspective view of the structure4600. The structure4600includes a first column4702and a second column4704of load bearing elements (e.g., elements4602-4608). The structure4600may also include pivot points4706, described in more detail below with respect toFIG. 48.

InFIG. 48, a top view of the support structure4600is shown. Three pivot points are present, including the central pivot point4802, and the column pivot points4804and4806. The pivot points4802-4806may be formed as a narrowed section of material and may be thickness controlled to impart any desired amount of stiffness to the pivot point.

The columns4702and4704may pivot together on the central pivot point4802. In addition, the first column4702may pivot on the pivot point4806independently of the second column4704. Similarly, the second column4704may pivot on the pivot point4804independently of the first column4702. The structure4600thereby responds to and provides ergonomic or balanced support for loads placed on the structure4600.

FIG. 52shows a multiple tier pixelated support structure5200. The structure5200may include first-tier load bearing elements such as those labeled5202,5204,5206,5208,5210, and5212. In the implementation shown inFIG. 52, the load bearing elements5202-5212are triangular. Triangular load bearing elements may provide enhanced conformance to the body part that the load bearing elements support, in comparison with other load bearing element shapes. However, other load bearing element shapes may also be used in conjunction with or instead of the triangular shapes.

The load bearing elements5202-5212may form groups. For example, the structure5200includes hexagonal load bearing element groups, three of which are labeled5214,5216, and5218. Living hinges5220may connect individual load bearing elements to form a load bearing surface from one or more load bearing elements and/or one or more groups.

The load bearing surface may take many different shapes and sizes. As examples, the load bearing surface may extend in two dimensions to provide a chair seat, or may extend primarily in one dimension as a linear strip of load bearing elements. The load bearing surface may also take on form in three dimensions. For example, the load bearing surface may take a convex shape. The convex shape may match the body shape of a relatively small chair occupant. The living hinges5220may flatten to accommodate relatively large chair occupants on the load bearing surface. As the surface adapts to the contour of the sitter's buttocks, the living hinges5220will expand and flatten.

The structure5200may also include load bearing element support arms such as rockers connected to the load bearing elements. Three of the rockers are labeled5222,5224, and5226. The rockers may connect through a rocker connection such as a shockmount to a second-tier support arm. One of the rocker connections is labeled5228and one of the second-tier support arms is labeled5230inFIG. 52. The rocker connections5228may accord the rockers a lower spring rate than the load bearing elements, may take vertical load compressively, and may allow angular rocking with force feedback. In one implementation, the rocker connections5228are ball and socket joints.

The rockers may provide support to any one or more of the load bearing elements. InFIG. 52, the rockers provide support to three of the six load bearing elements in each hexagonal group. For example, the load bearing elements5202,5206, and5210are directly supported by rockers, while load bearing elements5204,5208, and5212are supported through living hinges to adjacent load bearing elements5202,5206, and5210.

The load bearing elements may attach to the rockers in many ways. The load bearing elements may attach through a snap fit joint, such as a ball and socket joint, through a fastener, or in other manners. The second tier support arms5230may be straight or may include curvature, for example, to meet manufacturability process constraints. The second tier support arms5230and rockers may be a single injection molded part or may be individually formed.

One or more of the second-tier support arms may emerge from a support arm connection such as the connection labeled5232. The support arm connections5232may be implemented as noted above with regard to the rocker connections5228. The support arm connection be part of a third-tier support arm, such as the third-tier arms labeled5234and5236.

The hexagonal load bearing element groups5214,5216and5218form a tri-hex load bearing surface that is supported by the second tier. Specifically, second tier support arms that emerge from a common support arm connection may each support one of the load bearing element groups. Accordingly, eighteen load bearing elements may perform load balancing at the same rate. The center of the tri-hex surface may be located under pre-selected anatomical areas, such as the ischial tuberosites, under the thigh centerline, or other areas and may keep forces balanced at that point. The third-tier support5238may then proportion loads between or among the functional areas. The third tier support5238may vary the ratio of the length of its arms to give proportionally higher loads in any given location.

As shown inFIG. 52, the third-tier support arms5234and5236may be part of a third-tier support5238. The third-tier support5238may include a coupling5240. The coupling5240may connect to structural elements such as pins, rods, or other fasteners to connect the structure5200to adjacent structures, for example to extend the load bearing surface in a given direction.

The third-tier support5238may be H-shaped and may be a separately molded part. The H-shape support5238includes the support arms5234and5236connected by a bar on which the coupling5240may be located. The third-tier support5238may connect through the bar to an underlying support frame through pinning, for example with a steel pin, a molded snap fit connection, a fastener, or other connection.

One or more of the tiers may alone or in combination with other tiers provide curvature to the load bearing surface. The curvature is self-tailoring and adapts to the body part to the supported by the load bearing surface. For example, a load bearing surface that forms a chair seat have a curvature consistent with the buttocks.

The elements shown inFIG. 52may be formed through an injection molding process, a vacuum or heat forming process, or by other processes. The elements may be formed from polypropylene, thermoplastic elastomers, Hytrel™ material, polyethylene, polyamide (with or without fillers), glass filed nylon, fiberglass, spring steel, or other materials. Each element may be adjusted in size, shape, dimension, and/or material to impart a selected stiffness to any portion of the load bearing surface. The load bearing surface may thereby provide tailored support for selected body parts across the surface.

A layer of material may be placed over the top of the load bearing elements. The material may be a knit fabric or other interface between the load and the load bearing elements.

FIG. 53shows an expanded view of the rockers5222,5224, and5226. The rocker connection5228and a portion of the support arm5230is also shown. The rockers5222,5224, and5226connect to the load bearing elements through connection points5302,5304, and5306. The connection points5302,5304, and5306may implement a snap fit connection or joint, such as a ball and socket joint, may be a fastener, or may provide a connection in other manners.

The rockers5222,5224, and5226may provide approximately one inch of separation between the load bearing element connection points5302,5304, and5306. The triangular load bearing elements5202-5212may correspondingly be approximately 1 inch on a side. Other sizes and distances may also be used.

The rockers5222,5224, and5226and/or the support arms5230may be formed from a glass filed nylon or Polybutylene Terephtalate (PBT) material. The rocker connection5228(and support arm connections5232) may be a shockmount formed from Hytel material, Santoprene material, or other material. The rocker connection5228may be implemented with a softness between a Shore D 35 and a Shore A 80-95 softness. Other softnesses may be selected.

FIG. 54shows a bottom view of a torsional pixelated support structure5400. The structure5400may form all or part of a chair seat or other support structure. The structure5400includes load bearing elements, four of which are labeled5402,5404,5206, and5208. The load bearing elements may be formed and interconnected as described above with reference toFIGS. 44 and 45. As will be described in more detail below, however, one or more connecting bars may be replaced with connecting bars with a longer effective length.

In the structure5400, the connecting bar between pairs of load bearing elements may include a support post. The support post5410may extend away form the load bearing elements and may provide a mechanical stop to displacement of the load bearing elements. Alternatively, a supporting structural member behind the structure5400may include stops that extend up toward the structure5400. The support post5410extends from the connecting bar between the load bearing elements5402and5404. Support posts for neighboring pairs of load bearing elements are labeled5412,5414, and5416.

In the implementation shown above, the connecting bars (e.g., connecting bar4436) between pairs of load bearing elements were substantially straight. The connecting bars, for example those between pairs of load bearing elements, may take other shapes at any tier, however. As shown inFIG. 54, the connecting bars in the second and third tiers are S-shaped.

Four of the S-shaped bars in the second tier are labeled5418,5420,5422, and5424. The S-shaped bars5418-5424may connect together at one end, and may connect at the other end to the support posts5410-5416. In a manner analogous to the connect bar4442, additional S-shaped bars may connect together multiple pairs of load bearing elements in the second tier. For example, the S-shaped bar5426connects between the S-shaped connecting bars5412and5416to connect together two pairs of load bearing elements. Similarly, the S-shaped bar5428connects between the S-shaped connecting bars5422and5424to connect together the two pairs of load bearing elements5402-5408.

At the third tier, S-shaped bars may also connect together larger sets of load bearing elements. As shown inFIG. 54, the S-shaped bar5430connects four pairs of load bearing elements5432. The S-shaped bar5434connects four pairs of load bearing elements5436.

The S-shape may provide an effectively longer connecting bar. InFIG. 54, the S-shaped bars are folded back on themselves and consume approximately the same amount of space as a relatively straight connection bar, yet are approximately three times longer. The additional length increases the amount of flexing and deflecting in the connecting bars.

Each connecting bar may have an individually selected cross section or height, shape, material, or other characteristics. The height of a connection bar may vary along its length (e.g., by approximately 0.010 inches). The thickness of each connection bar may increase between tiers (e.g., by approximately 0.020 inches). The cross section may be increased or decreased, for example, to stiffen or loosen the connecting bar.

In one implementation, the S-shaped bars in the second tier (e.g., the connection bar5418) may be 0.090 inches thick, and may increase from 0.375 inches to 0.475 inches in height along their length. The height of the S-shaped bars in the third tier (e.g., the connection bar5430) may be 0.110 inches thick and may increase from 0.475 inches in height to 0.575 inches in height along their length.

The structure5400may include mounting points. The mounting points may connect to an underlying frame or other structure using fasteners, a snap-fit, an interference fit, or in other manners. Three mounting points5438,5440, and5442are shown.

The mounting points may establish independent pixelated support structures through their connections to the support structure5400. For example, the portion of the pixelated support structure5400between the mounting points5438and5440may move and react independently from the portion of the pixelated support structure5400between the mounting points5440and5442. Accordingly, a single structure5400may react as multiple independent support structures.

In the third tier, S-shaped connection bars may couple the load bearing elements and second tier to the mounting points. InFIG. 54, for example, the S-shaped connection bar5444connects the S-shaped connection bars5430and5434to the central mounting point5440. The S-shaped connection bar5446connects the S-shaped connection bars5430and5434to the peripheral mounting point5442.

The structure5400may include a peripheral support5448. The support5448may provide a connection point for a fabric or other covering for the structure5400. The size and shape of the support5448may vary widely. In one implementation, the support5448is 0.75 inches wide and 0.09-0.10 thick. The support5448may connect to the structure5400through connection tabs5450to one or more load bearing elements. Alternatively or additionally, the support5448may connect to the structure5400through a connection5452to a mounting point, such as the mounting point5440.

Alternatively, the support may include bellows, folds, or other deformable structures5454. The deformable structures5454may provide a degree of flexibility in the support5448. In one implementation the deformable structures5454may be aligned with the space between one or more load bearing elements in a pair.

One or more of the S-shaped connecting bars may include webbing in one or more locations. The webbing may vary in thickness between implementations, and may be, for example, approximately 0.025 inches thick. For example, the connecting bar5434includes webbing5456and5458between each fold of the connecting bar5434. The webbing may be centrally vertically located between the folds in the connecting bars. The webbing may help prevent lateral bending of the load bearing elements.

In other embodiments, the bottom tier of S-shaped connection bars may have a curved rolling surface. The rolling surfaces may be designed to permit rolling motion in one or more planes. For example, the rolling surfaces may permit left to right rolling motion.

The structure5400may be fabricated through a molding process, for example. The load bearing elements, connection bars between the load bearing elements, and support5448may be formed in a first injection mold. The lower tiers may be formed in a second injection mold. A snap fit, interference fit, fastener or other connection may be made between the first and second molded portions to form the structure5400.

FIG. 55shows a bottom perspective view5500of a torsional pixelated support structure. The perspective view5500(and side view5800) shows that the mounting points may be formed from a triangular truss structure. The mounting points may be formed in other manners, however.FIG. 56shows an enlarged view5600of a portion of the support structure5400.FIG. 57shows a side view5700of the support structure5400.FIG. 58shows a side view5800of the support structure5400.

FIG. 59shows triangular load bearing elements5902,5904,5906,5908,5910, and5912arranged in a hexagonal set5914. The load bearing elements5902-5912are shown as equilateral triangles approximately 3 inches on a side. However, the load bearing elements5902-5912may vary widely in size, shape, and material. In other implementations, the load bearing elements5902-5912may be 0.5-1.5 inches on a side, for example approximately 1 inch on each side. The load bearing element size and shape may vary across any support structure that incorporates the load bearing elements5902-5912, for example to tailor support to a specific body part. The load bearing elements may be formed from polypropylene, thermoplastic elastomers, Hytrel™ material, polyethylene, polyamide (with or without fillers), glass filed nylon, fiberglass, or other materials.

FIG. 60shows a bottom view of a pixelated support structure6000that incorporates hexagonal sets of the load bearing elements. Three hexagonal sets are labeled6002,6004, and6006. The hexagonal set6002, for example, includes the load bearing elements6008,6010,6012,6014,6016, and6018.

As shown inFIG. 60, the load bearing elements may be connected together to form load bearing surfaces. The load bearing surface may include injected molded sections that define multiple connected load bearing elements. One or more bridges between load bearing elements may permit the load bearing elements to twist or flex (e.g., an approximately flat bar bridge), to displace from one another (e.g., a bar connection with a U-shape or undulation out of the plane of the load bearing elements), or permit the load bearing elements freedom of motion or rotation in other directions or along other axes. Alternatively, one or more of the bridges may be substantially stiff and may hold the load bearing elements in place without rotation or translation.

Alternatively or additionally, one or more individually formed load bearing elements may be connected through individually formed bridges between the load bearing elements. For example, the bridge6020connects the load bearing elements6008and6010. The bridge6020may be located approximately half way along one edge of each load bearing element6008,6010, although other locations are also suitable. The bridges may be secured to the load bearing elements using fasteners such as screws, bolts, interference fits, snap fits, or other securing mechanisms.

The bridge6020may take many shapes and forms to provide any desired freedom of movement or flexion to the load bearing elements. For example, the bridge6020may include an approximately flat connection between each load bearing element to prevent load bearing elements from separating from one another. Alternatively, the bridge6020may include a U-shape, undulation, or other displacement of material between load bearing elements that permits the load bearing elements to displace away from one another.

The load bearing surface may include multiple tiers of support elements, including the load bearing elements as a first tier.FIG. 61shows a perspective view of a portion of a second support tier and a portion of a third support tier. As shown inFIG. 61, the second tier of support elements may include connection bars6102between load bearing elements (e.g., between the load bearing elements6104and6106). The connection bars6102may be vertically displaced from the load bearing elements by shockmounts6108.

The connection bars6102may be made from spring steel to impart substantially stiffness to the connection bar. Alternatively, one or more connection bars6102may be made from nylon, or other flexible materials. The connection bars may be secured to the shockmounts6108through a screw, bolt, snap fit, or other fastener. Similarly, the shockmounts6108may be secured to the load bearing elements6104,6106through a screw, bolt, snap fit, threaded connection, or other fastening mechanism. In other implementations, the shockmounts6108may be implemented as injected molded ball and socket joints.

The third support tier may include conical springs6110, cantilever springs, or other support elements connected to the first tier. The third support tier may connect to an underlying frame. The underlying frame may define a chair seat, chair back, or any other load bearing structure.

The multiple tier load bearing surface shown inFIG. 60provides support over substantially all of its surface. As an individual sits on the surface, multiple support elements in the second and third tiers take up the load and provide support. For example, the conical springs, located at the centers of the hexagonal sets, assist neighboring conical springs to take up loads that are centered between the springs.

The pixelated support elements and structures may be employed in a wide range of designs for supporting the body, including seats, backrests, mattresses, and the like. The pixelated support elements and structures provide enhanced ergonomic body support structures that may be adapted to provide excellent fit and comfort tailored to individual body parts, as well as healthy support for the body, across a wide range of individual body types.