Patent Publication Number: US-2021177149-A1

Title: Seating arrangement and method of construction

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/997,128, filed on Jun. 4, 2018, entitled “SEATING ARRANGEMENT AND METHOD OF CONSTRUCTION,” which claims benefit of U.S. Provisional Patent Application No. 62/517,270, filed on Jun. 9, 2017, entitled “SEATING ARRANGEMENT AND METHOD OF CONSTRUCTION,” and U.S. Provisional Patent Application No. 62/653,275, filed on Apr. 5, 2018, entitled “SEATING ARRANGEMENT AND METHOD OF CONSTRUCTION,” the entire disclosures of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     Various embodiments relate to a seating arrangement, and in particular to a seating arrangement that includes various combinations of a pair of flexibly resilient shell members, a flexibly resilient support member and a rigid support member that cooperate to form a deformable and flexibly resilient four-bar linkage, and an active back arrangement having a movement that may be separated from movement of an associated seat support arrangement. 
     BRIEF SUMMARY 
     In one embodiment, a seating arrangement includes a base member, and an integrally formed support member coupled to the base member and supporting a seat moveable from an upright position to a reclined position, wherein a portion of the support member is bendable as the seat moves from the upright position to the reclined position such that a first side of the support member is put in tension and a second side generally opposite the first side is put in compression, and wherein the first side includes a tensile substrate so that the first side has a higher modulus of elasticity than the second side. 
     In another embodiment, a seating arrangement includes a first portion of a seating component, a second portion of the seating component movable with respect to the first portion between a first position and a second position, and a transition portion of the seating component positioned between and integral with the first and second portions and configured to deform as the second portion is moved between the first and second position, the transition portion including a side in tension as the transition portion is deformed, a side under compression as the transition portion is deformed and a plurality of longitudinally-aligned strands where a majority of the plurality of strands of the transition portion are positioned in the side in tension, wherein the plurality of strands bias the second portion from the second position toward the first position. 
     In yet another embodiment, a seating arrangement includes a first portion of a seating component, a second portion of the seating component movable with respect to the first portion between a first position and a second position and a transition portion of the seating component positioned between and integral with the first and second portions and configured to deform as the second portion is moved between the first and second position, the transition portion including a first side, a second side located opposite the first side, a first material have a first modulus of elasticity, and second material having a second modulus elasticity that is greater than the first modulus of elasticity, wherein a majority of the second material is located in the first side of the transition portion, and wherein the second material biases the second portion from the second portion toward the first position. 
     In still yet another embodiment, a seating arrangement includes a first portion of a seating component, a second portion of the seating component movable with respect to the first portion between a first position and a second position, and a transition portion of the seating component positioned between the first and second portions and configured to deform as the second portion is moved between the first and second position, the transition portion including a first material and second material that is different than the first material, the first material comprising a thermoplastic, wherein the transition portion has a modulus of elasticity of within the range of from about 700,000 psi to about 5,000,000 psi, and wherein the second material biases the second portion from the second position toward the first position. 
     In another embodiment, a seating arrangement includes a seating surface configured to support a seated user, a back member extending upward substantially upward from the seating surface and movable between an upright position and a reclined position, and a supporting arrangement. The supporting arrangement includes a first portion, a second portion movable with respect to the first portion between a first position and a second position and a third portion between the first portion and the second portion and that is configured to deform as the second portion is moved between the first and second positions, the third portion including a side in tension as the third portion is deformed and a side under compression as the third portion is deformed, wherein the third portion of the supporting arrangement includes a first material having a first modulus of elasticity and second material having a second modulus of elasticity that is greater than the first modulus of elasticity, a majority of second material being positioned in the side in tension of the third portion. 
     In yet another embodiment, a seating arrangement subassembly for use in making a chair component includes first and second sections each including a plurality of longitudinally-aligned strands, and a tape carrier molded to the first and second sections, wherein at least portions of the first and second sections are exposed from the tape carrier and the exposed portions are spaced in different planes. 
     In yet another embodiment, a seating arrangement includes a base member, and an integrally formed support member coupled to the base member and supporting a seat moveable from an upright position to a reclined position, wherein a first portion of the support member positioned rearwardly of the base member is bendable such that an upper layer of the first portion is put in tension, and wherein a second portion of the support member positioned forwardly of the base member is bendable such that a lower layer of the second portion is put in tension, wherein the upper layer of the first portion and the lower layer of the second portion are reinforced with at least one tensile substrate. 
     In still yet another embodiment, a seating arrangement includes a first portion, a second portion and a third portion, the second and third portions movable with respect to the first portion between respective first and second positions, and a first transition portion positioned between the first and second portions and a second transition portion positioned between the first and third portions, the first, second, third, first transition and second transition portions being an integral, single piece, the first and second transition portions configured to deform as the second and third portions are moved between the first and second positions, respectively, the transition portions each including a side in tension as the respective transition portion is deformed, a side under compression as the respective transition portion is deformed and a plurality of longitudinally-aligned strands where a majority of the plurality of strands of each transition portion are positioned in the side in tension of that transition portion, wherein the plurality of strands bias the second and third portions from the second position toward the first position thereof, wherein the first, second, third, first transition and second transition portions cooperate to form a first side and a second side that is opposite the first side, and wherein the side in tension of the first transition portion is located in the first side and the side in tension of the second transition portion is located in the second side. 
     In still yet another embodiment, a chair shell arrangement includes a seating portion, a curved transition portion and a backrest portion, wherein a pair of laterally spaced longitudinal slots are formed in portions of the seating portion and the transition portion thereby defining a central region and laterally spaced side regions, wherein the central region is moveable relative to the side regions during recline of the chair, and an over molded layer covering the pair of slots. 
     In another embodiment, a seating arrangement includes a first portion of a seating component, a second portion of a seating component moveable with respect to the first portion between a first position and second position, a transition portion of a seating component positioned between the first portion and the second portion, where the transition portion is configured to deform as the second portion is moved from the first position to the second position, the transition portion including a surface in tension as the transition portion is deformed and a surface under compression as the transition portion is deformed, and a stranded material attached to the surface in tension of the transition area. 
     In yet another embodiment, a flexible hinge arrangement includes a first portion, a second portion movable with respect to the first portion between a first position and a second position, and a transition portion positioned between the first and second portions and configured to deform as the second portion is moved between the first and second position, the transition portion including a side in tension as the transition portion is deformed, a side under compression as the transition portion is deformed and a plurality of longitudinally-aligned strands where a majority of the plurality strands of the transition portion are positioned in the side in tension, wherein the first, second and transition portions are a single, integral piece, and wherein the plurality of strands bias the second portion from the second position toward the first position. 
     In still yet another embodiment, a flexible hinge arrangement includes a first portion, a second portion and a third portion, the second and third portions movable with respect to the first portion between respective first and second positions, and a first transition portion positioned between the first and second portions and a second transition portion positioned between the first and third portions, the first, second, third, first transition and second transition portions being an integral, single piece, the first and second transition portions configured to deform as the second and third portions are moved between the first and second positions, respectively, the transition portions each including a side in tension as the respective transition portion is deformed, a side under compression as the respective transition portion is deformed and a plurality of longitudinally-aligned strands where a majority of the plurality of strands of each transition portion are positioned in the side in tension of the transition portion, wherein the plurality of strands bias the second and third portions from the second position toward the first position thereof, wherein the first, second, third, first transition and second transition portion cooperate to form a first side and a second side that is opposite the first side, and wherein the side in tension of the first transition portion is located in the first side and the side in tension of the second transition portion is located in the second side. 
     Another embodiment includes a method of making a reinforced chair component that includes positioning a tape carrier having exposed first and second sections of glass fiber tape in a mold in a manner such that the first and second sections of tape are spaced apart in different planes within the mold, and molding a shell over the tape carrier and first and second sections of tape, wherein the first section of tape is positioned adjacent an upper surface of the shell and the second section of tape is positioned adjacent a lower surface of the shell relative to the chair component. 
     Yet another embodiment includes a method of constructing a seating arrangement including providing a first material comprising a plurality of strands extending lengthwise with respect to one another, placing the first material in a mold, and molding a second material to the first material to form a seating component having a first portion, a second portion, and a deformable transition portion positioned between the first and second portions, a side in tension as the transition portion is deformed and a side under compression as the transition portion is deformed, wherein a majority of the strands are positioned in the side in tension. 
     Still yet another embodiment includes a method of constructing a seating arrangement including providing a first material comprising a plurality of strands, placing the first material in a mold, and molding a second material to the first material to form a seating component a tensile side and a compression side, wherein a majority of the strands are positioned in the tensile side. 
     Still yet another embodiment includes a method of constructing a seating arrangement including providing an insert member that includes as first material and a plurality of strands extending lengthwise with respect to one another, the insert member having a first modulus of elasticity, placing the insert member in a mold, and molding an outer body about at least a portion of the insert member such that at least of majority of the insert is positioned in a tensile side of the outer body than a compression side of the outer body, the outer body comprising a second material having a second modulus of elasticity that is less than the first modulus of elasticity. 
     Another embodiment includes a method of making a reinforced chair component including positioning a first section of glass fiber tape on a first side of a mold, positioning a second section of glass fiber tape on a second side of the mold such that the two sections of tape are at least partially spaced apart from one another within the mold, and injecting a polymeric material into the mold over the first and second sections of tape to mold the component, wherein the first section of tape is positioned adjacent a first surface of the component and the second section of tape is positioned adjacent a separate surface of the component at least partially spaced apart from one another in the molded component. 
     Yet another embodiment includes a method of making a chair component including molding a shell having a seating portion, a curved transition portion and a backrest portion, molding a pair of laterally spaced longitudinal slots in portions of the seating portion and the transition portion thereby defining a central region and laterally spaced side regions in the shell, and overmolding a material on the seating portion and transition portion and covering the slots. 
     Yet another embodiment includes a method of constructing a seating arrangement including providing a first material comprising a plurality of strands extending lengthwise with respect to one another, providing a second material comprising a plurality of strands extending lengthwise with respect to one another, placing the first and second materials in a mold such that the first and second materials are at least partially offset from one another, and molding a third material to the first material to form a seating component having a first side and a second side, wherein a majority of the plurality of strands of the first material are positioned in the first side of the seating component and a majority of the plurality of strands of the second material are position in the second side of the seating component, and such that the first and second material are at least partially offset from one another. 
     In yet another embodiment, a seating arrangement includes a seat portion configured to support a seated user, a back portion extending substantially upward from the seat portion and movable with respect to the portion between an upright position and a reclined position, and a biasing member that is separate from the seat portion and the back portion and that includes a stranded material and a side in tension and a side in compression as the back portion is moved from the upright position toward the reclined position, wherein the stranded material includes a plurality of longitudinally-extending strands, wherein a majority of the plurality of strands are located within the first side, and wherein the biasing member biases the back portion from the reclined position to the upright position. 
     In another embodiment, a seating arrangement includes an upwardly extending back arrangement movable between an upright position and reclined position, and a seat arrangement, that includes a first link member extending substantially horizontally and configured to support a seated user thereon, a second link member space from the first link member, and a third link member operably coupled to the first link member and to the second link member. The third link member is substantially flexible along at least a portion of a length thereof, and flexes as the back arrangement moves between the upright and the reclined positions, and is configured to bias the back arrangement from the reclined position toward the upright position. The third link comprises a first material having a first bend stiffness and a second material having a second bend stiffness that is greater the first bend stiffness. 
     In another embodiment, a seating arrangement includes an upwardly extending back arrangement movable between an upright position and reclined position, and a seat arrangement, that includes a first link member extending substantially horizontally and configured to support a seated user thereon, a second link member space from the first link member, and a third link member operably coupled to the first link member and to the second link member, the third link member being substantially flexible along at least a portion of a length thereof, wherein the third link flexes as the back arrangement moves between the upright and the reclined positions and is configured to bias the back arrangement from the reclined position toward the upright position, wherein the third link includes a body portion having a first bend stiffness and a reinforcement member having a second bend stiffness that is greater that the first bend stiffness, the body portion including a thermoplastic, and the reinforcement member including a stranded material configured to bond to the thermoplastic of the first material. 
     Another embodiment includes a method of constructing a seating arrangement that includes providing at least one reinforcement member comprising a first material having a first bend stiffness, placing a reinforcement member in a first mold, molding at least one structural seat element to the reinforcement member such that the reinforcement member and the at least one structural seat element cooperate to form a single-piece insert member, removing the insert member from the first mold, placing the insert member in a second mold, and molding an outer body about at least a portion of the insert member, the outer body comprising a second material having a second bend stiffness that is less than the first bend stiffness, wherein at least a portion of the outer body and at least a portion of the insert member are configured as a link that flexes as a back arrangement of a seating arrangement moves between an upright position and a reclined position and is configured to bias the back arrangement from the reclined position toward the upright position. 
     Various embodiments of the seating arrangements described here may provide a platform with the proper fit and function for comfortably supporting a seated user and may reduce or shift costs by reducing associated part counts, manufacturing costs, and labor costs. The seating arrangement includes an uncomplicated, durable, and visually appealing design capable of a long operating life by reducing part wear associated with more complex designs, allows increased precision during manufacture and assembly, may reduce noise associated with the operation of more complex systems, includes the ability to store useful energy during operation of the overall system, allows for a relative reduction in weight of the associated system, and is particularly well adapted for the proposed use. Further the apparatus and methods as described herein provide a compliant, resiliently flexible arrangement that may be configured as a relatively complex geometry at a relatively low cost, and/or may significantly reduce the complexity required via mechanical-type arrangements. 
     These and other features, advantages, and objects of various embodiments 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 
         FIG. 1  is a perspective view of an embodiment of a seating arrangement; 
         FIG. 2  is a side elevational view of the embodiment of the seating arrangement shown in  FIG. 1  with a back assembly shown in an upright position in solid line and a reclined position in dashed line; 
         FIG. 3  is a perspective view of the embodiment of the chair shown in  FIG. 1  with a fabric cover removed; 
         FIG. 4  is a cross-sectional side elevational view of the embodiment of the chair shown in  FIG. 1 , taken along the line IV-IV,  FIG. 3  with the back assembly shown in the upright position; 
         FIG. 5  is a cross-sectional side elevational view of the embodiment of the chair shown in  FIG. 1 , taken along the line IV-IV,  FIG. 3 . with the back assembly shown in the recline position; 
         FIG. 6  is a cross-sectional side elevational view of the embodiment of the chair shown in  FIG. 1 , taken along the line VI-VI,  FIG. 3 ; 
         FIG. 7  is a cross-sectional side elevational view of the embodiment of the chair shown in  FIG. 30 , taken along the line VII-VII,  FIG. 1 ; 
         FIG. 8  is a perspective view of a rear shell member with internal components shown in dashed lines; 
         FIG. 8A  is an enlarged, partial side view of the area VIIIA,  FIG. 7 ; 
         FIG. 8B  is an enlarged, partial side view of the area VIIIB;  FIG. 7 ; 
         FIG. 9  is a top plan view of the rear shell member with internal components shown in dashed lines; 
         FIG. 10  is a bottom plan view of the rear shell member with internal components shown in dashed lines; 
         FIG. 11  is a perspective view of forward and rearward reinforcement members; 
         FIG. 12  is a perspective view of an insert; 
         FIG. 13  is a cross-sectional side elevational view of a first mold assembly and the insert; 
         FIG. 13A  is a flow chart illustrating a first method for constructing a seat arrangement; 
         FIG. 13B  is a flow chart illustrating a second method for constructing a seat arrangement; 
         FIG. 14A  is a cross-sectional side elevational view of a second mold assembly and the rear shell member; 
         FIG. 14B  is an enlarged cross-sectional side view of the area XIVB,  FIG. 14A ; 
         FIG. 15  is a perspective view of a stop member; 
         FIG. 16  is a perspective view of a non-weight activated seat structure; 
         FIG. 17  is a side-elevational schematic view of a seat shell member; 
         FIG. 18  is a side-elevational schematic view of another embodiment of a seat shell member; 
         FIG. 19  is an exploded perspective view of an alternative embodiment of a seating arrangement; 
         FIG. 20  is an exploded view of an alternative embodiment of a seating arrangement; 
         FIG. 21  is an enlarged view of area XXI,  FIG. 20 ; 
         FIG. 22  is a rear perspective view of a front shell member and a rear shell member; 
         FIG. 23  is an enlarged view of area XXIII,  FIG. 22 ; 
         FIG. 24  is an enlarged view of area XXIV,  FIG. 20 ; 
         FIG. 25  is an enlarged view of area XXV,  FIG. 22 ; 
         FIG. 26  is a cross-sectional view of the front and rear shell members engaged with one another; 
         FIG. 27  is a perspective view of a table arrangement; 
         FIG. 28  is a cross-sectional view of the table arrangement taken along the line XXVIII-XXVIII,  FIG. 27 ; 
         FIG. 29  is an enlarged, cross-sectional view of the area XXIX,  FIG. 28 ; and 
         FIG. 30  is an enlarged, cross-sectional view taken along the line XXX-XXX,  FIG. 27 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the seating embodiment as shown in  FIG. 1 . However, it is to be understood that certain embodiments 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 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. The various embodiments disclosed herein may be utilized within and incorporated into various seating arrangements, including office chares, general office seating, vehicle seating, home seating, aircraft seating, stadium seating, theater seating, and the like. 
     The reference numeral  10  ( FIG. 1 ) generally designates an embodiment of a seating arrangement. In the illustrated example, the seating arrangement  10  is provided in the form of an office chair assembly and includes a cantered base assembly  12  abutting a floor surface  14 , a seat assembly  16  and a back assembly  18  each supported above the base assembly  12 , and a pair of arm assemblies  20 . In the illustrated example, the chair assembly  10  ( FIG. 2 ) includes a front or a first shell member  22  and a rear or second shell member  24 . The shell members  22 ,  24  may each be formed as a single, integral piece or comprise multiple, individual components as described below. The shell members  22 ,  24  may each comprise a flexibly resilient polymer material such as any thermoplastic, including, for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermal set material, including, for example, epoxies; or any resin-based composites, including, for example, carbon fiber or fiberglass, thereby allowing each of the shell members  22 ,  24  to conform and move in response to forces exerted by a user. Although a polymer material is preferred, other suitable materials may also be utilized, such as metals, including, for example, steel or titanium; plywood; or a composite material including plastics, resin-based composites, metals and/or plywood. A variety of other suitable energy-storing materials may also be utilized. 
     The front shell member  22  ( FIGS. 2 and 3 ) includes a horizontally-extending bottom or first portion  26  which may be configured to support a seated user, a vertically-extending upper or second portion  28  extending upwardly from the first portion  26  and which may be configured to support the back of a seated user, and an arcuately-shaped transition portion  30  extending between the first portion  26  and the second portion  28 . The first portion  26  includes a forward portion  32  and a rearward portion  34 , while the second portion  28  includes a lower portion  36 , an upper portion  38  where the arcuately-shaped, forwardly convex mid-portion  30  is located therebetween and configured to support the lumbar region of a user&#39;s back. 
     In the illustrated example, the front shell member  22  further includes a pair of laterally-spaced slots  44  extending in a fore-to-aft direction from a mid-portion  39  of the second portion  28  to the intermediate portion  42  of the second portion  28 , thereby dividing the front shell member  22  into an inner portion  48  and a pair of outer portions  50 . The division of the inner portion  48  from the outer portions  50  allows the inner portion  48  to flex separately from the outer portions  50  during recline of the back assembly  18  from an upright position A to a recline position B. As best illustrated in the  FIGS. 4 and 5 , the flexing of the front shell member  22  during recline is such that the inner portion  48  flexes less than the outer portions  50  such that the outer portions  50  descend relative to the inner portion  48 , thereby allowing additional flexibility in the front shell member  22  while providing adequate support for the seated user via the inner portion  48 . The differentiation of flexure of the inner portion  48  and the outer portions  50  causes the second portion  28  of the front shell member  22  to move from the reclined position toward the upright position and exert an increased pressure to the back of a seated user as the force exerted on the inner portion  48  is increased, such as a force exerted by the weight of a seated user. 
     The front shell member  22  ( FIGS. 3 and 6 ) further includes a pair of C-shaped reliefs or apertures  52  each defining a tab  54 . Each tab  54  has a laterally-extending flexing region  56  of relative reduce thickness thereby promoting flexure of each tab  54  in this region as described below. 
     The rear shell member  24  includes a horizontally-extending bottom or first portion  58 , a vertically-extending upper or second portion  60  extending upwardly from the first portion  58 , and an arcuately-shaped transition portion  62  extending between the first portion  58  and the second portion  60 , and as described in greater detail below. 
     In assembly, an intermediate portion  42  of the second portion  28  of the front shell member  22  located between the upper portion  38  and the mid-portion  39  is connected to an upper portion  64  of the second portion  60  of the rear shell member  24 , such as by sonic welding, an adhesive, integral molding, mechanical fasteners, and the like. The front shell member  22  and the rear shell member  24  may be configured so as to define a gap  66  therebetween. 
     The chair assembly  10  ( FIGS. 1 and 2 ) may include laterally-extending support members or linkage members, including a pair of forward support or linkage members  68  and a rearward support or linkage member  70 , each extending between the second portion  28  of the front shell member  22  and the second portion  58  of the rear shell member  24 . In the illustrated example, the forward support members  68  are flexibly resilient along the length thereof, while the rearward support member  70  is relatively rigid. The forward support members  68  are integrally formed with the rear shell member  24  and rigidly attached to the tabs  54  of the front shell member  22 , while the rearward support member  70  is integrated with the rear shell member  24  and rigidly attached to the front shell member  22 . It is noted that in the other embodiments the front support member  68  and the rearward support member  70  may be formed as separate pieces, or as integral portions of the front shell member  22  and/or the rear shell member  24 . Further, in the illustrated example, the inner portion  48  cooperates with the forward support member  68  and the rearward support member  70  to form a control mechanism that synchronizes the rearward movement of the first portion  26  of the front shell member  22  with reclining movement of the second portion  28  of the front shell member  22  as further described below. 
     In the present example, the first portion  58  ( FIGS. 6 and 7 ) of the rear shell member  24  includes a laterally-extending flexing region  72  of relative reduced thickness located fore of the attachment location of the rearward support member  70  with the rear shell member  24 . The forward support member  68  includes a laterally-extending flexing region  74  of relative reduced thickness located at a lower end of the forward support member  68  such that flexure of the forward support member  68  is concentrated in the flexing region  74  while the remainder of the forward support member  68  may be relatively rigid and may remain relatively straight. The forward support member  68  connects to each of the tabs  54  aft of the flexing region  56 . Referring to  FIGS. 4 and 5 , it is noted that the rearward support member  70  remains rigid during recline, while the second portion  28 , the second portion  58  and the forward support member  68  flex, with the flexing regions or flexing zones  56 ,  72 ,  74  flexing a greater amount than the remainder of each of the associated components. It is noted that while the present examples are described as including flexible zones that comprise reduced thickness, other configurations may also be used, such as flexible zones created via the use of apertures, cut-outs, reduced widths and general configuration where the bending stiffness of the structure is reduced relative to the remainder of the structure. As previously noted the various thicknesses of the linkages or members comprising the overall supporting flexible four-bar linkage may be varied so as to provide specific support and bending characteristics previously described. The configuration as described above provides adequate flexure to the front shell member  22  while allowing an outer perimeter edge  76  of the front shell member to remain continuous and without breaks or reliefs, thereby providing a continuous outer aesthetic edge, while simultaneously reducing or eliminating wear of a supported cover assembly  78  ( FIGS. 1 and 7 ) typically caused by repeated flexing of a supporting chair surface. In the illustrated example, the cover assembly  78  includes a flexible resilient substrate layer  80  supported by the front shell member  22 , a thermal plastic foam layer  82  molded to the substrate layer  80 , and a fabric cover  84  thermally set to the foam layer  82 . Alternatively, the fabric cover may be wrapped about the foam layer  82  and secured to an underside of the substrate layer  80  by separate mechanical fasteners such as staples (not shown) or to integral fasteners (not shown) integrally molded with the substrate layer  80 , and/or secured about the foam layer  82  and the substrate layer  80  by a drawstring arrangement (not shown). In the illustrated example, the foam layer  82  and the fabric cover  84  are both continuous and free from irregularities along the edges thereof, such as apertures, reliefs, cut-outs, stitching, pleats, and the like. In an alternative embodiment, the continuous outer perimeter edge  76  of the front shell member  22  may provide an uninterrupted edge about which to wrap the fabric cover  84 . In another alternative arrangement, a separate outermost shell (not shown) comprising a molded thermal plastic may replace the cover assembly  78  and provide an outer, user supporting surface eliminating the need for a fabric-type cover. 
     In one embodiment, and as noted above, the forward support members  68  and the rearward support member  70  are integrally formed with the rear shell member  24 . In the present embodiment, the rear shell member  24  ( FIGS. 8-10 ) includes an outer body  86  molded about a pair of resiliently flexible forward reinforcement or biasing members  88  ( FIGS. 8-11 ), a relatively flexible rearward reinforcement or biasing member  90 , a central connector body  92  ( FIGS. 10 and 12 ) and the rearward support member  70 . The resiliently flexible forward reinforcement members  88  and the resiliently flexible rearward reinforcement member  90  each include a fiber tape that includes a substrate material such as nylon molded about a stranded material such as fiberglass or carbon fibers, however other suitable materials may also be used. In the present embodiment, the stranded material includes a plurality of strands or fibers  89  and preferably comprises fiberglass due to the bonding properties between fiberglass and thermoplastic. Further, the plurality of strands  89  are preferably similarly oriented lengthwise with respect to one another and along the fore-to-aft length of each of the resiliently flexible forward reinforcement members  88  and the flexible rearward reinforcement member  90 . In the instant example, the resiliently flexible forward and rearward reinforcement members  88 ,  90  each comprise a continuous glass, extruded “tape,” as commercially available from Plasticomp of Winona, Minn., which allows the reinforcement member  88 ,  90  to shape to or assume the same basic shape of the article or component the reinforcement member  88 ,  90  is molded, adhered or attached to. The central connector body  92  also includes a central aperture  93  for receiving a column  95  of the base assembly  12  therethrough. 
     In a first molding process ( FIG. 13A ), the resiliently flexible reinforcement members  88 ,  90  ( FIG. 13 ) are provided (step  200  ( FIG. 13A )) and are placed into a mold assembly  100  (step  202 ) and may be held in place by mechanical abutment structures, such as suction cups, and/or by an electrostatic force between the reinforcement members  88 ,  90  and the face of the mold. In the present example, the fiber tape is relatively flexible and are entirely spaced from one another. In another example, the multiple pieces of the fiber tape may be positioned with respect to one another external to the mold assembly  100 , and may at least partially overlap with one another, and may then be placed within the mold assembly  100  as a pre-oriented or positioned grouping. The central connector body  92  is then molded about a forward edge  101  of the rearward reinforcement member  90  and a rearward edge  103  of the forward reinforcement members  88 , thereby connecting the same with one another, while the rearward support member  70  is molded onto the rearward reinforcement member  90 , thereby resulting in a single-piece insert  102  ( FIG. 12 ) that includes the forward and rearward reinforcement members  88 ,  90 , the central connector body  92  and the rearward support member  70  (step  204 ). The central connector body  92  and the rearward support member  70  each preferably comprise a thermoplastic material. The insert  102  is then removed from the mold assembly  100  (step  206 ). In a second molding process ( FIG. 13B ) the insert  102  may then be placed in a second mold assembly  104  ( FIG. 14A ) (step  208 ), where the outer body  86  is molded about the insert  102  (step  210 ). As previously noted, the outer body  86  may comprise a flexibly resilient polymer material such as thermoplastic, including for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermal set material, including, for example, epoxies; or resin-based composites, including, for example, carbon fiber or fiberglass. In the instant example, the outer body  86  is molded about the insert  102  such that the resiliently flexible forward reinforcement members  88  ( FIG. 8A ) are located in a tensile side  155  proximate a forward or tensile surface  106  ( FIG. 8 ) where the tensile side  155  is put in tension and the compression side  157  is under compression when the flexing zone  72  deforms as the back assembly  18  is moved from the upright position A to the reclined position B. The resiliently flexible rearward reinforcement member  90  ( FIG. 8B ) is located in a tensile side  151  proximate an upper or tensile surface  108  opposite a rearward or compression side  161  proximate a rearward or compression surface  163 , where the tensile side  151  is put in tension and the compression side  161  is under compression when the flexing zone  74  deforms as the back assembly  18  is moved from the upright position A toward the reclined position B. The selected placement of the reinforcement member  88 ,  90  flexibly reinforce the areas of the overall structure most subject to bending during recline of the back assembly  18 , such as, for example, the flexing regions  72 ,  74 . It is noted that locating the reinforcement members  88 ,  90  just beneath the outer surfaces  106 ,  108  provides the outer body  86  with an overall outer surface that may be easily treated, such as by painting, powder coating, and the like. It is further noted that this molding process or method also generally allows the construction of various parts, components, subassemblies and structures that incorporate multi-layers providing various and varied mechanical properties, as well as pre-constructed features into a single-piece element. With reference to  FIGS. 14A and 14B , the insert  102  is placed within an interior of the second mold  104 . A locking member  105  extends into the apertures  93  of the central connector body  92  and engages the central connector body  92  to hold the insert member  102  in place within the second mold  104 . The second mold  104  includes a first gate  107  that provides a flow path  109  and a second gate  111  that provides a flow path  113 . It is noted that the first and second flow paths  109 ,  113  direct the molded material onto the resiliently flexible reinforcement member  88 ,  90 , respectively, in such a manner so as to force the resiliently flexible reinforcement members  88 ,  90  onto the lower and upper faces of the second mold  104  thereby holding the reinforcement members  88 ,  90  in position during the molding process. Preferably, the outer body  86  comprises a polypropylene, nylon 66 GF, or nylon 6 GF while the fiberglass strands comprises long glass resins. Further, the outer body  86  preferably comprises equal to or greater than 20% glass by volume, more preferably equal to or greater than 55% glass by volume, and most preferably equal to or greater than 70% glass by volume. 
     The embodiment of the chair assembly  10  as described above provides a cost effective, reclinable seating arrangement with highly repeatable bending properties and support characteristics. Preferably, the forward support members  68  provide a bend stiffness of between about 
     
       
         
           
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     The forward, flexible support members  68  further have a maximum thickness along a majority of the length of the forward support members  68  of less than equal to about 0.5 inches, more preferably of less than or equal to about 0.25 inches, and most preferably of between about 0.150 inches and about 0.040 inches. The resiliently flexible reinforcement members  56 ,  72  and  74  each have a modulus of elasticity or elastic modulus of preferably between about 700,000 psi and about 5,000,000 psi, more preferably of between about 700,000 psi and about 3,000,000 psi, even more preferably of between about 1,000,000 psi and about 2,000,000 psi, and most preferably of about 1,600,000 psi. The composite material of the resiliently flexible reinforcement members  56 ,  72 ,  74  is configured to store a significant amount of energy during deformation while simultaneously resisting fatigue failures. In addition, the composite material and configuration of the members  56 ,  72 ,  74  resists deformation in unwanted modes thereby preserving intended movement when subjected to disruptive forces. 
     The chair assembly  10  further includes a recline stop arrangement  120  ( FIG. 7 ). In the illustrated example, the stop arrangement  120  includes a stop member  122  ( FIG. 15 ) having a cylindrical body portion  124  that receives an upper end of a supporting column  95  therein, a flange  126  that extends about the body portion  124  and that cooperates with a lower coupler  128  to couple the rear shell member  24  and the stop member  122  with the column  95 , and a stop arm  130  extending rearwardly from the body portion  124 . The stop arm  130  extends through an aperture  132  in a front wall  134  of the rearward support member  70  such that a pair of stops  136  located at a distal end of the stop arm  130  are located within an interior space or cavity  138  of the rearward support member  70  defined between the front wall  134  and a rear wall  140 . The stop arm  130  and stops  136  cooperate to form a control rod. In operation, the rearward recline of the back assembly  18  from the upright position A toward the recline position B is limited by the stops  136  abutting the rear wall  140 , while a forward tilting of the back assembly  18  from the reclined position B toward the upright position A is limited by the stops  136  abutting the front wall  134 . It is noted that the present configuration provides a relatively open chair structure such that the components comprising the flexible four-bar linkage, the arm support structure and portions of the recline limiting arrangement are viewable, while the abutting stop components are concealed from view and within the existing supporting structures and specifically a component of the flexible four-bar linkage. 
     The present inventive flexible reinforcement arrangement and methods for employing the same may be utilized within various seating configurations and for various applications, seating assemblies, seating structures and seating elements. For example, the reinforcement arrangement may be utilized within weight activated seating arrangements, such as that shown in  FIGS. 1-7 , or within a non-weight activated seat structure  220 , as shown in  FIG. 16 . The seating structure  220  includes a seat shell member  222  having a horizontally-extending seat portion  224  and a vertically-extending back portion  226  moveable between an upright position and a reclined position similar to as previously discussed above with respect to the seating arrangement  10 . In the illustrated example, the shell member includes a U-shaped aperture  227  positioned within the seat portion  224  and extending partially into a transition area  228  located between the seat portion  224  and the back portion  226 . The aperture  227  is configured so as to create a bend portion  230  located toward each side of the shell  222  and that are adapted to flex as the back portion  226  moves between the upright and reclined positions. The seat structure  220  further includes a pair of resiliently flexible reinforcement members  232  similar in construction as the resiliently flexible reinforcement members  88 ,  90  as discussed above, and located within an upper or tensile side proximate a tensile surface  234  of the shell  222 , where the tensile side is in tension as the back portion moves from an upright to a reclined position. 
       FIG. 17  illustrates a schematic view of a seat shell member  240  that includes a seat portion  242  and a back portion  244 , where the shell member  240  is moveable between an upright position and a reclined position. The shell member  240  may include advantageously-located bend locations where the material of the shell member  240  is configured to bend more easily than the remainder of the shell member  240 . In the illustrated example, the shell member  240  may include a first bend location  246  positioned between the seat portion  242  and the back portion  244  providing bend characteristics within the shell member  240  as shown between the upright position X and a reclined position Y. Another potential application is a second bend location  248  located between a forward support portion  250  providing bend characteristics within the shell member  240  as shown between the upright position X and a reclined position Z. Additional applications may include similar arrangements located proximate a lumbar support region  252  ( FIG. 18 ) of a shell member  254 , proximate rear seat supporting locations  256  of a seat portion  258 , and/or connections  260  between a back portion  262  or other portions of the shell member  254  and a support frame or structure  264 . 
     The reference numeral  300  ( FIG. 19 ) generally designates another embodiment of the seating arrangement (where the flexible reinforcement construction of the rear shell member  24  as described above is used within various and multiple elements and components of the seating arrangement  300 . In the illustrated example, the seating arrangement or chair assembly  300  is similar to the chair assembly  10  previously described with the most notable exceptions being the inclusion of a first reinforcement member  302 , a second reinforcement member  304 , and the construction of the front shell member  306  via a multi-layer over-molding process. In the illustrated example, the chair assembly  300  includes the front or first shell member  306  and the rear or second shell member  308  that is similar to the previously described rear shell member  24 , where the front shell  306  is covered by a substrate layer or comfort surface  310  and a fabric cover assembly  312 . 
     The front shell member  306  includes an outer shell member  314  having a horizontally-extending bottom or first portion  316 , a vertically-extending upper or second portion  318  extending upwardly from the first portion  316 , and an arcuately-shaped transition portion  320  extending between the first portion  316  and the second portion  318 . The first portion  316  includes a forward portion  322  and a rearward portion  324 , while the second portion  318  includes a lower portion  326 , an upper portion  328  and an arcuately-shaped, forwardly convex mid-portion  330  located therebetween and configured to support the lumbar region of a user&#39;s back. The front shell member  306  further includes a pair of laterally-spaced slots  332  extending in a fore-to-aft direction similar to the slots  44  of the chair assembly  10  as previously described with respect to seating arrangement  10 . 
     The front shell member  306  further includes an inner shell portion  334  having a horizontally-extending bottom or first portion  336 , a vertically-extending upper or second portion  338 , and an arcuately-shaped transition portion  340  extending between the first portion  336  and the second portion  338 . In assembly, the inner shell portion  334  is over-molded over the outer shell member  314  such that the inner shell portion  334  covers or overlaps with at least a portion of the bottom portion  316 , the upper portion  318  and transition portion  320  at least in the area of the outer shell member  314  surrounding the slots  332 . Preferably, the inner shell portion  334  comprises a material that is more flexible than the material from which the outer shell member  314  is constructed, more preferably the inner shell portion  334  and outer shell member  314  each comprise a thermoplastic polymer, and most preferably, the outer shell member  314  comprises polyethylene terephthalate or polybutylene terephthalate, and the inner shell portion  334  comprises a thermoplastic polyolefin. 
     The chair assembly  300  further includes the reinforcement member  302  located in the transition portion  320  of the front shell member  306 , where the reinforcement member  302  may be substantially rigid or flexible resilient as describe below. The reinforcement member  302  is arcuately-shaped to match the arcuate shape of the transition portion  320 . In the illustrated example, the reinforcement member  302  may comprise a relatively stiff material, such as metal, and extend along the transition portion  320 , such that the reinforcement member  302  prevents the angle between the bottom portion  316  and the upper portion  318  from increasing as the upper portion  318  is moved from the upright position to the reclined position, thereby concentrating compliance or bending in the control arrangement forward of the transition portion  320 . 
     The chair assembly  300  further includes the structural reinforcement member  304  extending between the tabs  344  that are similar to the tabs  54  of the chair assembly  10  as described above. The reinforcement member  304  overlaps with an area of the bottom portion  316  of the shell member  306  so as to disperse forces transmitted between the rear shell  308  and the front shell  306  in the vicinity of the tabs  344 . In assembly, the reinforcement members  302 ,  304  are positioned within corresponding reliefs  345 ,  347  of the substrate layer  310 , respectively. 
     In the illustrated example, various components and elements may be constructed similar to the rear shell member  24  as previously described, and specifically may comprise a resiliently flexible reinforcement members  350 ,  352 ,  354 ,  356  overmolded on an outer body. Preferably, one or more structural reinforcement members comprise a substrate material such as nylon molded about a stranded material such as fiberglass or carbon fibers, however other suitable materials may be used, while the associated outer body may comprise a flexibly resilient polymer material such as any thermoplastic, including, for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermo set material, including for example, epoxies,; or any resin-based composites, including, for example, carbon fiber or fiberglass. 
     The reference numeral  300   a  ( FIG. 20 ) generally designated another embodiment of the seating arrangement. Since the seating arrangement or chair assembly  300   a  is similar to the previously described chair assembly  300 , similar parts appearing in  FIG. 19  and  FIG. 20  respectively are represented by the same, corresponding reference numeral, except for the suffix “a” in the numerals of the latter. In the illustrated example, the integral, single-piece resiliently flexible reinforcement member  360  includes a forward portion  362 , a rearward portion  364  and an arcuately-shaped transition portion  366  extending between the first portion  362  and the rearward portion  364 . The forward portion  362  is substantially rigid and extends between the tabs  344   a  that are similar to the tabs  54  of the chair  10  as described above, and overlaps with an area of the bottom portion  316   a  of the shell member  306   a  so as to disperse forces transmitted between the rear shell  308   a  and the front shell  306   a  in the vicinity of the tabs  344   a.  The rearward portion  364  is substantially rigid and extends upwardly from the forward portion  362  such that the rearward portion  364  is aligned with and structurally supports the mid-portion  330   a  of the upper portion  318   a  of the front shell  306   a.  The transition portion  366  includes a substantially rigid zone  370  that may be rigidified by a plurality of longitudinally-extending ribs  372  so as to disperse forces exerted on the mid-portion  330   a  by a seated user and structurally reinforce the same, and a resiliently flexible zone  373  positioned forwardly of the rigid zone  370 . The substantially rigid forward portion  362 , the substantially rigid rearward portion  364  and the substantially rigid zone  370  of the transition portion  366  cooperate to concentrate the deformation of the forward shell  306   a  in a portion of the forward shell  306   a  proximate the resiliently flexible zone  373 . In the present example, the resiliently flexible reinforcement member  360  may be constructed similarly to the rear shell member  24  as previously described where the flexible zone  373  of the resiliently flexible reinforcement member  360  includes a tensile side or side in tension proximate a tensile surface and a compression side or side under compression proximate a compression surface, where the tensile side is put in tension and the compression side is under compression when the flexible zone  373  deforms as the back assembly is moved from the upright position to the reclined position. Similar to the rear shell member  24 , the resiliently flexible reinforcement member  360  may include a tensile substrate in the form of a plurality of longitudinally-aligned glass fibers in-molded within an outer shell comprising a glass-filled nylon, preferably where a majority of the plurality of fibers are located within the tensile side, and more preferably where all of the plurality of fibers are located within the tensile side. 
     In assembly, the rearward portion of the resiliently flexible reinforcement member  360  is attached to the rear shell member  308   a  by a plurality of mechanical fasteners  378  that are received through corresponding apertures  380  of the resiliently flexible reinforcement member  360 , apertures  382  of the front shell member  306   a,  and into bosses  384  ( FIG. 21 ) of the rear shell member  308   a,  where the bosses  384  are received within corresponding reliefs  385  ( FIGS. 22 and 23 ) surrounded each of the apertures  382  of the front shell  306   a.  The rearward portion  364  and the forward portion  362  of the resiliently flexible reinforcement member  360  are received within corresponding reliefs  345   a,    347   a  of the substrate layer or comfort member  310   a,  while a central portion  386  of the substrate layer  310   a  extends over the transition portion  366  of the resiliently flexible reinforcement member  360 . A plurality of couplers  388  attach the substrate layer  310   a  to the front shell member  306   a.  The rear shell  308   a  ( FIGS. 22 and 24 ) also includes a forwardly-extending, integral engagement shelf  387  that engages a lip  389  ( FIG. 25 ) defined by a laterally-extending, elongated aperture  391  of the front shell  306   a  ( FIG. 26 ) such that the front shell  306   a  is coupled with the rear shell  308   a  in the vicinity of the engagement shelf  387  and lip  389  and such that forces exerted on the front shell  306   a  are supported by the rear shell  308   a.    
     The resiliently flexible reinforcement arrangements as described herein may also be utilized in other components or assemblies, such as, for example, other furniture components. For example, a resiliently flexible arrangement may be utilized within a table assembly  400  ( FIG. 27 ) that includes a work surface  402  supported by a frame assembly  404  ( FIG. 28 ) which is in turn supported by a plurality of legs  406 . In the instant example, the work surface  402  ( FIG. 29 ) includes a top surface  408 , a bottom surface  410  and an outer peripheral edge  412 , and comprises a tensile substrate  414  covered by a body portion  416  overmolded onto the tensile substrate  414  in a manner similar to the process described above with respect to the rear shell member  24  of the seating arrangement  10 . Preferably, the tensile substrate  14  includes a substrate material such as nylon molded about a stranded material such as fiberglass or carbon fibers, however other suitable materials may be used, while the associated outer body may comprise a flexibly resilient polymer material such as any thermoplastic, including, for example, nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermo set material, including for example, epoxies; or any resin-based composites, including, for example, carbon fiber or fiberglass. The tensile substrate  414  may be positioned in an area of the work surface  402  having a reduced thickness  418 , and preferably includes a plurality of longitudinally aligned strands such as glass fibers that extend in a radial direction across the area of reduced thickness  418  in mold within a poly material. In the illustrated example, the work surface  402  includes a peripheral lip  420  configured to deflect downwardly from an upright position C to a deflected position D upon exertion of sufficient force F. The outer body  416  is molded about the tensile substrate  414  such that the tensile substrate  414  is located in a tensile side  422  proximate an upper or tensile surface  424  opposite a bottom or compression side  426  proximate a bottom or compression surface  428 , where the tensile side  422  is put in tension and the compression side  426  is under compression when the area of reduced thickness or flexing zone  418  is deformed as the lip  420  is moved from the upright position C to the deflected position D, and such that the tensile substrate  414  biases the lip  420  from the deflected position D toward the upright position C. 
     In yet another embodiment, the resiliently flexible arrangement is utilized within a door arrangement  440  positioned within the work surface  402  and configured to allow access through the work surface  402  and into an interior  442  ( FIG. 30 ) of a wireway or wire trough  444  positioned below the work surface  402 . The door arrangement  440  includes a door  446  integrally connected to a body portion  448  of the work surface  402  via a flexing zone  450  having a relatively reduced thickness. The flexing zone  450  includes a tensile substrate  452  constructed similar the tensile substrate  414  described above and positioned within a tensile side  454  of flexing zone  450  opposite a compression side  456  thereof. The door arrangement  440  is configured such that a user may move the door  446  from the position E to the open position F thereby allowing access to the interior  442 , and such that the tensile substrate  452  biases the door  446  from the open position F toward the closed position E. 
     It is noted that in each of the aforedescribed embodiments, the seating arrangement and furniture arrangements are configured such that some, many, or all of the components may be visible from an exterior of the arrangements subsequent to the arrangements being completely manufactured and assembled, such that the visible components form an outer aesthetic appearance of the arrangement, or alternatively may be enclosed within an interior of the arrangement such that the components are not visible to the casual observer. In the case of the seating arrangement, components such as the forward support member, the rearward support member, the support member, as well as the stop arrangements as described may be at least partially visible from an exterior of the chair, and cooperate to form an overall outer aesthetic thereof. Certain embodiments may include some, many, or all of the components described herein. For example, an embodiment may include one or more apertures, one or more of the stop systems, and/or components or materials selected for performance purposes, e.g., to bias the seat arrangement to an upright position or for material strength requirements. In some embodiments, a selection of a particular component may influence the selection of various other components. For example, using a particular aperture or apertures may dictate what type of components or materials should be used for performance purposes and vice versa. 
     Various embodiments of the seating arrangements described herein may provide a platform with the proper fit and function for comfortably supporting a seated user that may also reduce or shift costs, for example by reducing associated part counts, manufacturing costs, and labor costs. Certain aspects of the seating arrangements may include an uncomplicated, durable, and visually appealing design capable of a long operating life, and particularly well adapted for the proposed use. 
     In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the described embodiments without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.