Seating components with laminated bonding material

A seating support arrangement includes a seating frame arrangement, a flexible cover member supported by the frame arrangement and configured to support a seated user, a surface layer covering at least a portion of the cover member and including a first surface facing the cover member and a second surface opposite the first surface, wherein the first surface of the surface layer includes first portions attached to the cover member interspaced with second portions that are not attached to the cover member, and an elastically resilient control arrangement supported by the frame arrangement and positioned between the cover member and one of the second portions such that the control arrangement is free to move with respect to the cover member and the surface layer, wherein elastic deformation of the control arrangement changes the geometrical configuration of the cover member.

BACKGROUND OF THE INVENTION

The present invention relates to a seating assembly, and in particular to a seating assembly that includes a laminated support surface, wherein the surface can be configured to enhance mechanical properties of a supporting cover material, as well as to control the geometrical configuration or shape of the overall supporting surface.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is a seating arrangement that includes a first seating support arrangement that comprises a frame arrangement, a flexible cover member supported by the frame arrangement and configured to support a seated user, and a control arrangement operably coupled to the cover member such that deformation of the control arrangement deforms the cover member. The seating arrangement further includes a second seating support arrangement that comprises a frame arrangement, a flexible cover member supported by the frame arrangement and configured to support a seated user, and a control arrangement operably coupled to the cover member such that deformation of the control arrangement deforms the cover member. The seating arrangement further includes a coupling assembly operably coupling the control arrangement of the second seating support arrangement with the control arrangement of the first seating support arrangement such that deflection of the supporting surface of the second seating support arrangement causes a deflection of the cover member of the first seating arrangement while the frame arrangement of the first seating support arrangement and the frame arrangement of the second seating support arrangement each remain substantially motionless.

Another aspect of the present invention is a seating arrangement that includes a first seating support arrangement that comprises a first frame arrangement defining a first interior space, a first flexible cover supported by the first frame arrangement and located within the first interior space, the first flexible cover configured to support a seated user, and a second seating support arrangement that comprises a second frame arrangement defining a second interior space, and a second flexible cover supported by the second frame arrangement and located within the second interior space, the second flexible cover configured to support a seated user. The seating arrangement further includes a coupling assembly operably coupling the second cover of the second seating support arrangement with the first cover of the first seating support arrangement such that deflection of the second cover of the second seating support arrangement causes a deflection of the first cover member of the first seating arrangement while the first frame arrangement of the first seating support arrangement and the second frame arrangement the second seating support arrangement each remain substantially motionless.

Still yet another aspect of the present invention is a seating arrangement that includes a first seating support arrangement that comprises a seating frame arrangement, a flexible cover member supported by the seating frame arrangement and configured to support a seated user, and a surface layer covering at least a portion of the cover member and including a first surface facing the cover member and a second surface opposite the first surface, wherein the first surface of the surface layer includes first portions attached to the cover member interspaced with second portions that are not attached to the cover member. The first seating support arrangement further comprises an elastically resilient control supported by the seating frame arrangement and positioned between the cover member and one of the second portions such that the control arrangement is free to move with respect to the cover member and the surface layer, wherein elastic deformation of the control arrangement changes the geometrical configuration of the cover member. The seating arrangement further includes a second seating support arrangement including a supporting surface adapted to support a user, and a coupling assembly operably coupling the support surface of the second seating support arrangement with the control arrangement of the first seating support arrangement such that deflection of the supporting surface of the second seating support arrangement causes a deflection of the cover member of the first seating arrangement.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The reference numeral10(FIG. 1) generally designates a seating arrangement embodying the present invention. In the illustrated example, the seating arrangement10comprises an office chair assembly, however, it is noted that the present invention may be incorporated into various seating arrangements, including but not limited to, office seating, vehicle seating, home seating, stadium seating, theater seating, and the like. The seating arrangement10includes a castered base assembly12abutting a supporting floor surface13, a control or support assembly14supported by the castered base assembly12, a seat assembly16and a back assembly18each operably coupled with the control assembly14, and a pair of arm assemblies20.

The seat assembly or seating support arrangement16(FIGS. 2 and 3A) includes a seating frame arrangement22including a recess24defined therein. The seat assembly16further includes a flexible cover member26that is supported by the seating frame22as described below. In the illustrated example, the flexible cover member26includes a first surface25and a second surface27opposite the first surface25, and comprises a woven fabric, however various materials may also be utilized, including non-woven fabrics, polymeric materials, leather, and the like. The seat assembly16further includes a surface layer28attached to the cover member26. As shown, the surface layer28comprises a sheet of polymeric film material such as a polyester, however other suitable materials may also be utilized depending upon the particular application and the mechanical properties and/or shape control required. In the illustrated example, the surface layer28includes a first surface29and a second surface31opposite the first surface29. The surface layer28further includes laterally extending first portions30attached to the cover member26and a plurality of laterally extending second portions32interspaced with the first portions30and which are not attached to cover member26, thereby creating a plurality of laterally extending tunnels4, as described below.

The seat assembly16further includes an elastically resilient control arrangement50that is supported by the seating frame22above the recess24, and is positioned between the cover member26and the surface layer28. In the illustrated example, the control arrangement50includes a pair of flexibly resilient flexing members52attached to the sides54of the seating frame22by mechanical fasteners56. The control arrangement50further includes a plurality of support members58coupled to and extending laterally between the flexing members52. In the illustrated example, the support members58comprise a plurality of flexibly resilient, tensioned wire members each having a circular cross-sectional configuration. However, it is noted that variously configured support members comprising various materials may be utilized.

As best illustrated inFIG. 3A, the seat assembly16is constructed such that the elongated support members58extend laterally through the tunnels34, and are allowed to freely move with respect to the cover member26and the surface layer28. Specifically, the seat assembly16is constructed by aligning the control arrangement50with the cover member26and the surface layer28such that the support members58of the control arrangement50are positioned between the cover member26and the surface layer28. The first portions30of the surface layer28are then attached to the second surface27of the cover member26, thereby creating the tunnels34within which the support members58extend and are allowed to freely move with respect to the cover member26and the surface layer28. In the illustrated example, the first surface29of the surface layer28is preferably bonded to the second surface27of the cover member26via thermal bonding, sonic welding, laser welding, and the like, however other attachment methods may be utilized, such as adhesion, stitching, and the like. As an overview,FIG. 4outlines the method for constructing the seating support arrangement16includes providing the frame arrangement100, providing the cover member102, providing the surface layer104, positioning the control arrangement between the cover member and the surface layer106, covering at least a portion of the cover member with the surface layer108, attaching the first portions of the surface layer with the cover member100, and coupling the cover member with the frame arrangement112. Of course, alternative step sequences may also be utilized, such as attaching the surface layer with cover member110prior to positioning the control arrangement with respect to the cover member and the surface layer106.

It is noted that the first surface29of the surface layer28in the areas aligned with the second portions32of the surface layer28may be pre-treated so as to prevent bonding of the second portions32of the surface layer28with the second surface27of the cover member26. Alternatively, a boundary layer33(FIG. 3B) may be positioned between the second portions32of the surface layer28and the second surface27of the cover member26such that the cover member26is prevented from bonding to the first surface29of the surface layer28at the second portions32thereof.

It is further noted that whileFIGS. 3A and 3Bshow the cover member26and the surface layer28being arranged with respect to one another such that the first surface25of the cover member26forms the outer aesthetic surface of the seating support arrangement16, the cover member26and the surface layer28may be arranged such that the surface layer28provides the outer aesthetic surface for the seating support arrangement16, such as that illustrated inFIG. 3C. In this arrangement, the surface layer28may be provided in a pattern onto the cover member26or have a pattern created thereon or therein to provide the outer aesthetic appearance of the seating support structure16either individually or in cooperation with the cover member26. Moreover, it is noted that the surface layer28may be transparent, translucent, or opaque, or combinations thereof.

Moreover, the surface layer28may be configured and/or patterned in a manner so as to cooperate with the cover member26to provide to or alter the mechanical properties of the cover member26. For example, the surface layer28may be attached to the cover member26such that the elastic modulus of the combination of the cover member26and the surface layer28together is different from the elastic modulus of the cover member alone, thereby allowing for localized areas of increased support provided to a user. An example of a method that may be utilized to construct a seating support arrangement with a varying elastic modulus includes providing a seating frame arrangement200(FIG. 5), providing a cover member having a first elastic modulus202, attaching a polymer film surface layer to a support area of the cover member such that the cover member and surface layer cooperate to provide a second elastic modulus in the support area that is greater than the first elastic modulus204, and supporting the cover member and the surface layer from the seating frame arrangement206.

In the illustrated example, the flexing members52are coupled to the seating frame22such that the flexing members52are flexed and biased in an upward direction60. As best illustrated inFIG. 7, a control assembly70includes a control input arrangement such as a control knob72configured to receive an input from a user and operably coupled to at least one of the pair of flexing members52via a Bowden cable74. In operation, a user may reconfigure the supporting surface76of the cover member26by flexing the flexible members52via the control knob72and the Bowden cable74between a first position A and a second position B. It is noted that while in the illustrated example, the control arrangement50is configured to adjust the shape of all or at least the majority of the support surface76, the control arrangement50and the surface layer28may be configured to affect, reconfigure or shape only a portion of the support surface76.

For example, the back assembly or seating support arrangement18is constructed in a similar manner to that of the previously described seat assembly16, but wherein the associated surface layer and/or control assembly do not extend over the entire supporting surface of the back assembly. In the illustrated example, the back assembly18includes a back frame80that includes a recess82, a cover member84and a surface layer86. The surface layer86includes a plurality of first portions88and second portions90that are coupled with the cover member84in a similar manner to that described above with respect to the surface layer28and the cover member26, thereby creating a plurality of laterally extending tunnels. A back control arrangement92is constructed similar to the control arrangement50of the seat assembly16and includes a pair of flexing members94operably coupled to the back frame80via a plurality of mechanical fasteners96, and a plurality of support members98extending through the tunnels located between the cover member84and the surface layer86. In the illustrated example, the surface layer86is aligned with a lower portion or lumbar region83of the cover member84and may or may not be aligned with and attached to an upper portion85of the cover member84. The back control arrangement92is aligned with only the lower portion83of the cover member84. In operation, a user may reconfigure a supporting surface87of the lower portion83of the cover member84in a similar manner to that described above with respect to the seat assembly16, or specifically by flexing the flexing member94via a control knob89and a Bowden cable91between a first position C and a second position D.

Alternatively, the present invention may be used to couple multiple support surfaces together, such that a force input exerted onto one support surface changes the shape of or reconfigures another support surface. For example, the chair10a(FIG. 8) may be configured such that an input force F exerted onto the seat assembly16aresults in a change of shape to the support surface87aof the back assembly via a control assembly93. Since the chair10ais similar to the previously described chair10, similar parts appearing inFIG. 7andFIG. 8are represented by the same reference numeral, except for the suffix “a” in the numerals of the latter. In the illustrated example, a Bowden cable95adirectly couples the flexing members94aof the control arrangement92aof the back assembly18awith the flexing members52aof the control arrangement50aof the seat assembly16a, such that the downwardly directed force F results in a downward deflection of the support surface76aof the seat assembly16afrom the position E to the position F, thereby causing the support surface87aof the back assembly18ato deflect from the position G to the position H. While the present example illustrates the automatic adjustment of a lumbar area of a seating back assembly due to a force exerted on a seating assembly by a seated user, it is noted that the concept of reconfiguring and/or reshaping various supporting surfaces as a result of forces exerted on the support surfaces of other supporting arrangements may be used between a wide variety of supporting surfaces and seating components including but not limited to seat assemblies, back assemblies, head rest assemblies, arm assemblies, and the like.

Similarly, the surface layer28may be configured and/or patterned in a manner so as to cooperate with the cover member26to alter the rigidity of the material of the cover member26alone, thereby allowing the cover member26to be pre-shaped prior to assembly with the remainder of the seating support arrangement16. For example, the surface layer28may be attached and molded with the cover member16so as to form three dimensional shapes with the cover member for increased structural integrity, improved aesthetics, improving ease of manufacturing and/or assembly, and the like. An example of a method that may be utilized to construct a seating support arrangement with a varying rigidity includes providing a seating support arrangement300(FIG. 6) providing a cover member having a first rigidity and a shaped area that is less than the total area302, attaching the polymer film surface layer to the shaped area such that the shaped area has a rigidity greater than the first rigidity304, shaping the shaped area into a three dimensional shape306, and attaching the cover member and the surface layer to the seating frame arrangement while the shaped area substantially retains the three dimensional shape308.