Abstract:
A method of assembling a chair component includes providing a first chair member, providing a second chair member moveable between a first position, wherein the second chair member is coplanar with the first chair member, and a second position, wherein the second chair member is parallel with the first chair member, and wrapping a cover member about the first and second chair members. The method further includes providing a drawstring operably coupled with the cover member, drawing the cover member about the first and second chair members when the second chair member is in the first position, fixing an effective length of the drawstring while the second chair member is in the first postion, moving the second chair member from the first position to the second position, and securing the second chair member in the second position.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This is a continuation of U.S. patent application Ser. No. 14/029,284, filed Sep. 17, 2013, entitled “CHAIR ASSEMBLY,” and U.S. patent application Ser. No. 14/029,273, filed Sep. 17, 2013, entitled “CHAIR ASSEMBLY,” each of which claims the benefit of U.S. Provisional Patent Application 61/703,677 filed Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” 61/703,667 filed Sep. 20, 2012, entitled “CHAIR ARM ASSEMBLY,” 61/703,666 filed Sep. 20, 2012, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” 61/703,663 filed Sep. 20, 2012, entitled “CHAIR BACK MECHANISM AND CONTROL ASSEMBLY,” 61/703,659 filed Sep. 20, 2012, entitled “CONTROL ASSEMBLY FOR CHAIR,” 61/703,661 filed Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” 61/754,803 filed Jan. 21, 2013, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” 61/703,515 filed Sep. 20, 2012, entitled “SPRING ASSEMBLY AND METHOD,”61/733,661 filed Dec. 5, 2012, entitled “CHAIR ASSEMBLY,” and U.S. Design patent application Ser. No. 29/432,776 filed Sep. 20, 2012, entitled “CHAIR,” now U.S. Design Pat. No. D697729, the entire disclosures of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]    The present invention relates to a chair assembly, and in particular to an office chair assembly comprising a back assembly including an upholstery arrangement that wraps about a front surface and a rear surface of the back assembly. 
       SUMMARY OF THE INVENTION  
       [0003]    One aspect of the present invention is a method of assembling a chair component that includes providing a first chair member adapted to support a seated user, providing a second chair member moveable between a first position, wherein the second chair member is substantially coplanar with the first chair member, and a second position, wherein the second chair member is substantially parallel with the first chair member, wrapping a cover member about at least a portion of the first chair member and at least a portion of the second chair member, and providing a drawstring operably coupled with the cover member. The method further includes drawing the cover member about the at least a portion of the first chair member and the at least a portion of the second chair member when the second chair member is in the first position, fixing an effective length of the drawstring while the second chair member is in the first position, moving the second chair member from the first position to the second position, and securing the second chair member in the second position. 
         [0004]    Another aspect of the present invention is a method of assembling a chair component that includes providing a first chair member adapted to support a user and that includes a forwardly-facing front surface and a rearwardly-facing rear surface, wherein the first chair member further includes at least one raised portion extending rearwardly from the rear surface, wrapping a cover member about at least a portion of the first chair member, and providing a drawstring operably coupled with the cover member. The method further includes drawing the cover member about the at least a portion of the first chair member by the drawstring, aligning the cover with the at least one raised portion of the first chair member by the drawstring, and securing the drawstring to the first chair member with at least one fastener that is received within the at least one raised portion. 
         [0005]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0006]      FIG. 1  is a front perspective view of a chair assembly embodying the present invention; 
           [0007]      FIG. 2  is a rear perspective view of the chair assembly; 
           [0008]      FIG. 3  is a side elevational view of the chair assembly showing the chair assembly in a lowered position and in a raised position in dashed line, and a seat assembly in a retracted position and an extended position in dashed line; 
           [0009]      FIG. 4  is a side elevational view of the chair assembly showing the chair assembly in an upright position and in a reclined position in dashed line; 
           [0010]      FIG. 5  is an exploded view of the seat assembly; 
           [0011]      FIG. 6  is an enlarged perspective view of the chair assembly with a portion of the seat assembly removed to illustrate a spring support assembly; 
           [0012]      FIG. 7  is a front perspective view of a back assembly; 
           [0013]      FIG. 8  is a side elevational view of the back assembly; 
           [0014]      FIG. 9A  is an exploded front perspective view of the back assembly; 
           [0015]      FIG. 9B  is an exploded rear perspective view of the back assembly; 
           [0016]      FIG. 10  is an enlarged perspective view of an area X,  FIG. 9A ; 
           [0017]      FIG. 11  is an enlarged perspective view of an area XI,  FIG. 2 ; 
           [0018]      FIG. 12  is a cross-sectional view of an upper back pivot assembly taken along the line XII-XII,  FIG. 7 ; 
           [0019]      FIG. 13  is an enlarged perspective view of the area XIII,  FIG. 9B ; 
           [0020]      FIG. 14  is a cross-sectional side view of a comfort member taken along the line XIV-XIV,  FIG. 13 ; 
           [0021]      FIG. 15A  is an enlarged perspective view of the comfort member and a lumbar assembly; 
           [0022]      FIG. 15B  is a rear perspective view of the comfort member and the lumbar assembly; 
           [0023]      FIG. 16A  is a front perspective view of a pawl member; 
           [0024]      FIG. 16B  is a rear perspective view of the pawl member; 
           [0025]      FIG. 17  is a partial cross-sectional perspective view along the line XVIII-XVIII,  FIG. 15B ; 
           [0026]      FIGS. 18A-18D  are each exploded perspective views illustrating various steps of assembling a back support assembly, with a fixture shown in dotted line in  FIG. 18B , 
           [0027]      FIG. 19  is a perspective view of the area XIX,  FIG. 9B ; 
           [0028]      FIG. 20A  is a perspective view of the area XXA,  FIG. 18A ; 
           [0029]      FIG. 20B  is a perspective view of the area XXB,  FIG. 18B ; 
           [0030]      FIG. 20C  is an alternative embodiment to the embodiment shown in  FIG. 20A ; 
           [0031]      FIGS. 21A-21H  illustrate steps of securing a drawstring to the comfort member; 
           [0032]      FIG. 22  is a perspective view of the back assembly; 
           [0033]      FIG. 23  is a cross-sectional top view of the back assembly, taken along the line XXIII-XXIII,  FIG. 22 ; 
           [0034]      FIG. 24  is a perspective view of the back support assembly with outer components removed to show interior components thereof; 
           [0035]      FIG. 25  is a perspective view of a chair assembly; 
           [0036]      FIG. 26  is a front elevational view of the chair assembly of  FIG. 25 ; 
           [0037]      FIG. 27  is a first side elevational view of the chair assembly of  FIG. 25 ; 
           [0038]      FIG. 28  is a second side elevational view of the chair assembly of  FIG. 25 ; 
           [0039]      FIG. 29  is a rear elevational view of the chair assembly of  FIG. 25 ; 
           [0040]      FIG. 30  is a top plan view of the chair assembly of  FIG. 25 ; and 
           [0041]      FIG. 31  is a bottom plan view of the chair assembly of  FIG. 25 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0042]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIGS. 1 and 2 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
         [0043]    The reference numeral  10  ( FIGS. 1 and 2 ) generally designates a chair assembly embodying the present invention. In the illustrated example, the chair assembly  10  includes a castered base assembly  12  abutting a supporting floor surface  13 , a control or support assembly  14  supported by the castered base assembly  12 , a seat assembly  16  and back assembly  18  each operably coupled with the control assembly  14 , and a pair of arm assemblies  20 . The control assembly  14  ( FIG. 3 ) is operably coupled to the base assembly  12  such that the seat assembly  16 , the back assembly  18  and the arm assemblies  20  may be vertically adjusted between a fully lowered position A and a fully raised position B, and pivoted about a vertical axis  21  in a direction  22 . The seat assembly  16  is operably coupled to the control assembly  14  such that the seat assembly  16  is longitudinally adjustable with respect to the control assembly  14  between a fully retracted position C and a fully extended position D. The seat assembly  16  ( FIG. 4 ) and the back assembly  18  are operably coupled with the control assembly  14  and with one another such that the back assembly  18  is movable between a fully upright position E and a fully reclined position F, and further such that the seat assembly  16  is movable between a fully upright position G and a fully reclined position H corresponding to the fully upright position E and the fully reclined position F of the back assembly  18 , respectively. 
         [0044]    The base assembly  12  includes a plurality of pedestal arms  24  radially extending and spaced about a hollow central column  26  that receives a pneumatic cylinder  28  therein. Each pedestal arm  24  is supported above the floor surface  13  by an associated caster assembly  30 . Although the base assembly  12  is illustrated as including a multiple-arm pedestal assembly, it is noted that other suitable supporting structures maybe utilized, including but not limited to fixed columns, multiple leg arrangements, vehicle seat support assemblies, and the like. 
         [0045]    The seat assembly  16  ( FIG. 5 ) includes a relatively rigid seat support plate  32  having a forward edge  34 , a rearward edge  36 , and a pair of C-shaped guide rails  38  defining the side edges of the seat support plate  32  and extending between the forward edge  34  and the rearward edge  36 . The seat assembly  16  further includes a flexibly resilient outer seat shell  40  having a pair of upwardly turned side portions  42  and an upwardly turned rear portion  44  that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat shell  40  is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE). In assembly, the outer seat shell  40  is secured and sandwiched between the seat support plate  32  and a plastic, flexibly resilient seat pan  46  which is secured to the seat support plate  32  by a plurality of mechanical fasteners. The seat pan  46  includes a forward edge  48 , a rearward edge  50 , side edges  52  extending between the forward edge  48  and the rearward edge  50 , a top surface  54  and a bottom surface  56  that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan  46  includes a plurality of longitudinally extending slots  58  extending forwardly from the rearward edge  50 . The slots  58  cooperate to define a plurality of fingers  60  therebetween, each finger  60  being individually flexibly resilient. The seat pan  46  further includes a plurality of laterally oriented, elongated apertures  62  located proximate the forward edge  48 . The apertures  62  cooperate to increase the overall flexibility of the seat pan  46  in the area thereof, and specifically allow a forward portion  64  of the seat pan  46  to flex in a vertical direction  66  with respect to a rearward portion  68  of the seat pan  46 , as discussed further below. The seat assembly  16  further includes a foam cushion member  70  that rests upon the top surface  54  of the seat pan  46  and is cradled within the outer seat shell  40 , a fabric seat cover  72 , and an upper surface  76  of the cushion members  70 . A spring support assembly  78  ( FIGS. 5 and 6 ) is secured to the seat assembly  16  and is adapted to flexibly support the forward portion  64  of the seat pan  46  for flexure in the vertical direction  66 . In the illustrated example, the spring support assembly  78  includes a support housing  80  comprising a foam and having side portions  82  defining an upwardly concave arcuate shape. The spring support assembly  78  further includes a relatively rigid attachment member  84  that extends laterally between the side portions  82  of the support housing  80  and is located between the support housing  80  and the forward portion  64  of the seat pan  46 . A plurality of mechanical fasteners  86  secure the support housing  80  and the attachment member  84  to the forward portion  64  of the seat pan  46 . The spring support assembly  78  further includes a pair of cantilever springs  88  each having a distal end  90  received through a corresponding aperture  92  of the attachment member  84 , and a proximate end  94  secured to the seat support plate  32  such that the distal end  90  of each cantilever spring  88  may flex in the vertical direction  66 . A pair of linear bearings  96  are fixedly attached to the attachment member  84  and aligned with the apertures  92  thereof, such that the linear bearing  96  slidably receives the distal ends  90  of a corresponding cantilever springs  88 . In operation, the cantilever springs  88  cooperate to allow the forward portion  64  of the seat pan  46 , and more generally the entire forward portion of seat assembly  16  to flex in the vertical direction  66  when a seated user rotates forward on the seat assembly  16  and exerts a downward force on the forward edge thereof. 
         [0046]    The back assembly  18  ( FIGS. 7-9B ) includes a back frame assembly  98  and a back support assembly  99  supported thereby. The back frame assembly  98  is generally comprised of a substantially rigid material such as metal, and includes a laterally extending top frame portion  100 , a laterally extending bottom frame portion  102 , and a pair of curved side frame portions  104  extending between the top frame portion  100  and the bottom frame portion  102  and cooperating therewith to define an opening  106  having a relatively large upper dimension  108  and a relatively narrow lower dimension  110 . 
         [0047]    The back assembly  18  further includes a flexibly resilient, plastic back shell  112  that includes a forwardly-located first portion  119  having an upper portion  114  with an upper edge  121 , a lower portion  116 , a pair of side edges  118  extending between the upper portion  114  and a lower portion  116 , a forwardly-facing surface  120  and a rearwardly-facing surface  122 , wherein the width of the upper portion  114  is generally greater than the width of the lower portion  116 , and the lower portion  116  is downwardly tapered to generally follow the rear elevational configuration of the frame assembly  98 . The back shell  112  further includes a rearwardly-located second portion  123  having an upper edge  125 , a lower edge  127  and a pair of side edges  129  extending between the upper edge  125  and the lower edge  127 . The second portion  123  is generally aligned with the upper portion  114  of the first portion  119  such that the upper edge  125  and the side edges  129  of the second portion  123  are generally aligned with the upper edge  121  and the side edges  118  of the first portion  119 , respectively, as described below. 
         [0048]    A lower reinforcement member  115  attaches to hooks  117  ( FIG. 9A ) of lower portion  116  of the first portion  119  of the back shell  112 . Reinforcement member  115  includes a plurality of protrusions  113  that engage reinforcement ribs  134  to prevent side-to-side movement of lower reinforcement member  115  relative to the back shell  112 . 
         [0049]    The first portion  119  of the back shell  112  also includes a plurality of integrally molded, forwardly and upwardly extending hooks  124  ( FIG. 10 ) spaced about the periphery of the upper portion  114  thereof. An intermediate or lumbar portion  126  is located vertically between the upper portion  114  and the lower portion  116  of the first portion  119  of the back shell  112 , and includes a plurality of laterally extending slots  128  that cooperate to form a plurality of laterally extending ribs  130  located therebetween. The slots  128  cooperate to provide additional flexure to the back shell  112  in the location thereof. Pairings of lateral ribs  130  are coupled by vertically extending ribs  132  integrally formed therewith and located at an approximate lateral midpoint thereof. The vertical ribs  132  function to tie the lateral ribs  130  together and reduce vertical spreading therebetween as the back shell  112  is flexed at the intermediate portion  126  thereof when the back assembly  18  is moved from the upright position E to the reclined position F, as described further below. The first portion  119  of the back shell  112  further includes a plurality of laterally-spaced reinforcement ribs  134  extending longitudinally along the vertical length of the first portion  119  between the lower portion  116  and the intermediate portion  126 . It is noted that the depth of each of the ribs  134  increases the further along each of the ribs  134  from the intermediate portion  126 , such that the overall rigidity of the back shell  112  increases along the length of the ribs from the intermediate portion  126  toward the lower portion  116 . 
         [0050]    The first portion  119  of the back shell  112  further includes a pair of rearwardly-extending, integrally molded pivot bosses  138  forming part an upper back pivot assembly  140 . The back pivot assembly  140  ( FIGS. 11 and 12 ) includes the pivot bosses  138  of the back shell  112 , a pair of shroud members  142  that encompass respective pivot bosses  138 , a race member  144 , and a mechanical fastening assembly  146 . Each pivot boss  138  includes a pair of side walls  148  and a rearwardly-facing concave seating surface  150  having a vertically elongated pivot slot  152  extending therethrough. Each shroud member  142  is shaped so as to closely house the corresponding pivot boss  138 , and includes a plurality of side walls  154  corresponding to side walls  148 , and a rearwardly-facing concave bearing surface  156  that includes a vertically elongated pivot slot extending therethrough, and which is adapted to align with the slot  152  of a corresponding pivot boss  138 . The race member  144  includes a center portion  158  extending laterally along and abutting the top frame portion  100  of the back frame assembly  98 , and a pair of arcuately-shaped bearing surfaces  160  located at the ends thereof. Specifically, the center portion  158  includes a first portion  162 , and a second portion  164 , wherein the first portion  162  abuts a front surface of the top frame portion  100  and second portion  164  abuts a top surface of the top frame portion  100 . Each bearing surface  160  includes an aperture  166  extending therethrough. 
         [0051]    In assembly, the shroud members  142  are positioned about the corresponding pivot bosses  138  of the back shell  112  and operably positioned between the first portion  119  of the back shell  112  and race member  144  such that the bearing surface  156  is sandwiched between the seating surface  150  of a corresponding pivot boss  138  and a bearing surface  160 . The mechanical fastening assemblies  146  each include a bolt  172  that secures a rounded abutment surface  174  of the bearing washer  176  in sliding engagement with an inner surface  178  of the corresponding pivot boss  138 , and threadably engages a corresponding boss member  168  of the back frame assembly  98 . In operation, the upper back pivot assembly  140  allows the back support assembly  99  to pivot with respect to the back frame assembly in a direction  180  ( FIG. 8 ) about a pivot axis  182  ( FIG. 7 ). 
         [0052]    The back support assembly  99  ( FIGS. 9A and 9B ) further includes a flexibly resilient comfort member  184  ( FIGS. 15A and 15B ) attached to the back shell  112  and slidably supporting a lumbar assembly  186 . The comfort member  184  includes an upper portion  188 , a lower portion  190 , a pair of side portions  192  having a plurality of apertures  189  spaced therealong to increase the flexure thereof, a forward surface  193  and a rearward surface  195 , wherein the upper portion  188 , the lower portion  190  and the side portions cooperate to form an aperture  194  that receives the lumbar assembly  186  therein. As best illustrated in  FIGS. 9B and 13 , the comfort member  184  includes a plurality of box-shaped couplers  196  spaced about the periphery of the upper portion  188  and extending rearwardly from the rearward surface  195 . Each box-shaped coupler  196  includes a pair of side walls  198 , a top wall  200  and a rear wall  204  that cooperate to form an interior space  202 . In assembly, the comfort member  184  ( FIGS. 12-14 ) is secured to the back shell  112  by aligning and vertically inserting the hooks  124  of the back shell  112  into the interior space  202  of each of the box-shaped couplers  196 . The comfort member  184  further includes a plurality of upholstery alignment and connection pads  199  extending rearwardly from the rearward surface  195  and spaced about the outer periphery of the comfort member  184 . As best illustrated in  FIG. 14 , the thickness t of the comfort member  184  in the region of the pads  199  is greater than the thickness t′ of the comfort member  184  in other regions of the comfort member  184 . In the illustrated example, the majority of the area of the comfort member  184  comprises the thickness t′. The pads  199  function to increase the structural rigidity of the comfort member  184  in the areas the upholstery arrangement is attached thereto, as well as to provide alignment features for properly aligning the upholstery arrangement with respect to the comfort member  184  during assembly, as described below. 
         [0053]    The comfort member  184  ( FIGS. 15A and 15B ) includes an integrally molded, longitudinally extending sleeve  206  extending rearwardly from the rearward surface  195  and having a rectangularly-shaped cross-sectional configuration. The lumbar assembly  186  includes a forwardly laterally concave and forwardly vertically convex, flexibly resilient body portion  208 , and an integral support portion  210  extending upwardly from the body portion  208 . In the illustrated example, the body portion  208  is shaped such that the body portion  208  vertically tapers along the height thereof so as to generally follow the contours and shape of the aperture  194  of the comfort member  184 . The support portion  210  is slidably received within the sleeve  206  of the comfort member  184  such that the lumbar assembly  186  is vertically adjustable with respect to the remainder of the back support assembly  99  between a fully lowered position I and a fully raised position J. A pawl member  212  selectively engages a plurality of apertures  214  spaced along the length of support portion  210 , thereby releasably securing the lumbar assembly  186  at selected vertical positions between the fully lowered position I and the fully raised position J. The pawl member  212  ( FIGS. 16A and 16B ) includes a housing portion  216  having engagement tabs  218  located at the ends thereof and rearwardly offset from an outer surface  220  of the housing portion  216 . A flexibly resilient finger  222  is centrally disposed within the housing portion  216  and includes a rearwardly-extending pawl  224 . 
         [0054]    In assembly, the pawl member  212  ( FIG. 17 ) is positioned within an aperture  226  located within the upper portion  188  of the comfort member  184  such that the outer surface  220  of the housing portion  216  of the pawl member  212  is coplanar with the forward surface  193  of the comfort member  184 , and such that the engagement tabs  218  of the housing portion  216  abut the rearward surface  195  of the comfort member  184 . The support portion  210  of the lumbar assembly  186  is then positioned within the sleeve  206  of the comfort member  184  such that the sleeve  206  is slidable therein and the pawl  224  is selectively engageable with the apertures  214 , thereby allowing the user to optimize the position of the lumbar assembly  186  with respect to the overall back support assembly  99 . Specifically, the body portion  208  of the lumbar assembly  186  includes a pair of outwardly extending integral handle portions  251  ( FIG. 18   d ) each having a C-shaped cross-sectional configuration that wraps about and guides along the respective side edge  192  of the back shell  112 . 
         [0055]    In operation, a user adjusts the relative vertical position of the lumbar assembly  186  with respect to the back shell  112  by grasping one or both of the handle portions  251  and sliding the handle assembly  251  along the back shell  184  in a vertical direction. A stop tab  228  is integrally formed within a distal end  230  and is offset therefrom so as to engage an end wall of the sleeve  206  of the comfort member  184 , thereby limiting the vertical downward travel of the support portion  210  of the lumbar assembly  186  with respect to the sleeve  206  of the comfort member  184 . 
         [0056]    The back support assembly  99  ( FIGS. 9A and 9B ) also includes a cushion member  252  having an upper portion  254  and a lower portion  256 , wherein the lower portion  256  tapers along the vertical length thereof to correspond to the overall shape and taper of the back shell  112  and the comfort member  184 , and a topper cushion  253  comprising a relatively thin foam material. 
         [0057]    The back support assembly  99  ( FIG. 18A ) further includes an upholstery arrangement or cover assembly  300  that houses the back shell  112 , the lumbar support assembly  186 , the cushion member  252  and a topper cushion  253  therein. In the illustrated example, the cover assembly  300  comprises a fabric material that may be elastically deformable in one or more directions. The cover assembly  300  includes a front side  302  and a rear side  304  that are sewn together along the respective side edges thereof to form a first pocket  306  having a first interior or inner space  308  that receives the comfort member  184 , the cushion member  252  and the topper cushion  253  therein, and a flap portion  310  that is sewn to the rear side  304  and cooperates therewith to form a second pocket  348  having a second interior or inner space  350  that receives the lumbar support assembly  186  therein. It is noted that the cushion member  252 , the comfort member  184  and the second portion  123  of the back shell  112  are assembled with the topper cushion  253  prior to assembly with the cover assembly  300 , and specifically are attached to a rear surface of the topper cushion  253  via an adhesive. 
         [0058]    In assembly, the first pocket  306  is formed by attaching the respective side edges of the front side  302  and the rear side  304  to one another such as by sewing or other means suitable for the material for which the cover assembly  300  is comprised, and to define the first interior space  308 . An edge of the flap portion  310  is then secured to the rear side  304  proximate a midsection  312  thereof. In the illustrated example, the comfort member  184  and the second portion  123  of the back shell  112  are placed within a fixture  301  ( FIG. 18B ) that holds the second portion  123  in a planar relationship to the comfort member  184 . The combination of the second portion  123  of the back shell  164 , the comfort member  184  and the cushion member  296  are then inserted into the interior space  308  of the first pocket  306  via an aperture  314  located on the rear side  304  ( FIG. 18B ). The upholstery cover assembly  300  is stretched about the cushion member  252 , the second portion  123  of the back shell  112  and the comfort member  184 , and is secured to the comfort member  184  by a plurality of apertures  320  that receive upwardly extending hook members  324  ( FIG. 19 ) therethrough. Alternatively, the cover assembly  300  may be configured such that apertures  320  are positioned to also receive T-shaped attachment members  322  therethrough. In the illustrated example, the attachment members  322  and the hook members  324  are integrally formed with the comfort member  184 . Each attachment member  322  is provided with a T-shaped cross-section or boat-cleat configuration having a first portion  328  extending perpendicularly rearward from within a recess  329  of the rear surface  256  of the comfort member  184 , and a pair of second portions  330  located at a distal end of the first portion  328  and extending outwardly therefrom in opposite relation to one another. One of the second portions  330  cooperates with the first portion  328  to form an angled engagement surface  332 . The recess  329  defines an edge  334  about the perimeter thereof. 
         [0059]    The cover assembly  300  is further secured to the comfort member  184  by a single, continuous drawstring  336  that extends through a drawstring tunnel  338  of the cover assembly  300 , which is captured within multiple attachment features of the second portion  123  of the back shell  112  and the comfort member  184  and is in turn secured to the attachment members  322 . Specifically, the drawstring  336  and drawstring tunnel  338  are aligned with and secured to the plurality of upholstery alignment and connection pads  199 ′ ( FIG. 20A ) similar to the pads  199  ( FIG. 20B ) of the comfort member  184  via a plurality of staples (not shown). Alternatively, the drawstring  336  and drawstring tunnel  338  are routed about hook members  313  ( FIG. 20C ) located near the corners between the bottom edge  127  and side edges  129  of the second portion  123  of the back shell  112 , and are captured by a plurality of couplers  315  each including a plurality of elastically resilient, interspaced teeth  317  and spaced about the periphery of the second portion  123 . The drawstring  336  and drawstring tunnel  338  are then aligned with the pads  199  of the second portion  123  to assure proper alignment of the cover assembly  300  with the back shell  112  and the overall back support assembly  99 . In the illustrated example, the drawstring  336  and drawstring tunnel  338  are secured to the second portion via a plurality of staples  319  which are inserted into the thicker pads  199 . 
         [0060]    As best illustrated in  FIGS. 21A-21H , the drawstring  336  is drawn taut and each free end of the drawstring  336  is then secured to an associated attachment member  322  in a knot-free manner and without the use of a mechanical fastener that is separate from the comfort member  184 , thereby fixing the effective length of the drawstring  336  through the remainder of the assembly process. The drawstring  336  is wrapped about the associated attachment member  322  such that the tension in the drawstring  336  about the attachment member  322  forces the drawstring  366  against the engagement surface  332  that angles towards the recess  329 , thereby forcing a portion of the drawstring  336  into the recess  329  and into engagement with at least a portion of the edge  334  of the recess  329  resulting in an increased frictional engagement between the drawstring  336  and the comfort member  184 . The lumbar assembly  186  is then aligned with the assembly of the cover assembly  300 , the cushion member  252  and the comfort member  184  such that the body portion  272  of the lumbar assembly  186  is located near the midsection  312  of the cover assembly  300 , and the support portion  210  of the lumbar assembly  186  is coupled with the comfort member  184  as described above. The flap portion  310  is then folded over the lumbar assembly  186 , thereby creating the additional pocket  348  ( FIG. 18D ) having the interior space  350 . A distally located edge  352  of the flap portion  310  is attached to the comfort member  184  by a plurality of apertures  354  with the flap portion  310  that receive the hooks  324  therethrough. The distal edge  352  may also be sewn to the rear side  304  of the cover assembly  300 . In the illustrated example, the side edges  356  of the flap portion  310  are not attached to the remainder of the cover assembly  300 , such that the side edges  356  cooperate with the remainder of the cover assembly  300  to form slots  360  through with the handle portions  251  of the lumbar assembly  186 . The second pocket  348  is configured such that the lumbar assembly  186  is vertically adjustable therein. 
         [0061]    The assembly of the cover assembly  300 , the cushion member  252 , the comfort member  184 , the lumbar assembly  186  and the second portion  123  of the back shell  112  are then attached to the first portion  119  of the back shell  112 . Specifically, the comfort member  184  and the second portion  123  of the back shell  112  are removed from the associated fixture ( 301 ), and the comfort member  184  is then attached to the first portion of the back shell via the hooks  124  and box-shaped couplers  196  as previously described. The second portion  123  of the back shell  112  is then rotated about the first portion  119  of the back shell  112  from a position where the second portion  123  is generally planar with the first portion  119 , as shown in  FIG. 18D , to a position where the second portion  123  is wrapped about the first portion  119  and is generally parallel therewith, as shown in  FIG. 8 . As best illustrated in  FIGS. 11 and 20A , the second portion  123  includes a plurality of rearwardly-extending T-shaped couplers  321 , while the first portion includes a plurality of cooperating slots  323  that releasably received the couplers  321  therein, thereby securing the second portion  123  in the second position. Proper alignment of the second portion  123  with the first portion  119  is provided via generally conically-shaped locators  351  ( FIG. 20A ) extending forwardly from the second portion  123  that locate and align with corresponding conically-shaped recesses  355  ( FIG. 24 ) extending into the rear surface of the first portion  119  of the back shell  112 . 
         [0062]    As best illustrated in  FIGS. 22 and 23 , the back assembly  18  is further configured to increase the comfort of the outer edges of the back support assembly  99  and improve the aesthetics thereof. Specifically, the flexibly resilient comfort member  184  includes a recessed pocket  400  that receives the cushion member  252  therein, such that the outer edge of the cushion member  252  is spaced inwardly from the outer edge of the comfort member  184 , thereby providing an aesthetically clean appearance to the outer peripheral edge of the overall back support assembly  99 . 
         [0063]    As noted above, the back assembly  18  ( FIG. 4 ) is reclinable between an upright position E and a reclined position F. During recline, a gap  402  opens between the top frame portion  100  of the frame assembly  98  and the lower edge  127  of the second portion  123  of the back shell  112 , as a result of flexure of the back support assembly  99  and pivoting of the back support assembly  99  about the pivot axis  182  in the direction  180 . In the illustrated example, a shield member  406  ( FIGS. 12 and 24 ) prevents access to the gap  402 , thereby reducing or eliminating a potential pinch-point for the user. The shield member  406  includes a body portion  408  secured to a rear surface of the first portion  119  of the back shell  112  by a plurality of screws  410  received within rearwardly-extending bosses  412  of the shield member  406 . The shield member  406  further includes an arcuately-shaped, downwardly concave engagement portion  414  that slidably tracks along the horizontal portion  100  of the frame assembly  98  and the center portion  158  of the race member  144  as the back assembly  18  is reclined and the back support assembly is flexed. 
         [0064]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.