Source: https://patents.google.com/patent/US9022476B2/en
Timestamp: 2019-04-20 15:39:08+00:00

Document:
A control assembly for a chair includes a base structure having a first pivot point and a second pivot point spaced from the first pivot point, a seat support structure having a forward portion pivotably coupled to an upper portion of the base structure for rotation about the first pivot point, a back support structure having a forward portion pivotably coupled to a lower portion of the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first and second positions, and a control link having a first end pivotably coupled to a rearward portion of the seat support structure for rotation about a third pivot point, and a second end pivotably coupled to a rearward portion of the back support structure for rotation about a fourth pivot point.
This application claims priority to U.S. Provisional Patent Application No. 61/703,677, filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,667, filed on Sep. 20, 2012, entitled “CHAIR ARM ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,666, filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” U.S. Provisional Patent Application No. 61/703,515, filed on Sep. 20, 2012, entitled “SPRING ASSEMBLY AND METHOD,” U.S. Provisional Patent Application No. 61/703,663, filed on Sep. 20, 2012, entitled “CHAIR BACK MECHANISM AND CONTROL ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,659, filed on Sep. 20, 2012, entitled “CONTROL ASSEMBLY FOR CHAIR,” U.S. Provisional Patent Application No. 61/703,661 filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” U.S. Provisional Patent Application No. 61/754,803 filed on Jan. 21, 2013, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” U.S. Design patent application No. 29/432,765 filed on Sep. 20, 2012 entitled “CHAIR,” and U.S. Design patent application No. 29/432,767 filed on Sep. 20, 2012, entitled “CHAIR,” the entire disclosures of which are incorporated herein by reference.
The present invention relates to a control assembly of a chair assembly, and in particular to a control assembly comprising a 4-bar linkage assembly adapted to control a movement of a seat support structure relative to movement of a back support structure.
One aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining an upper portion having a first pivot point and a lower portion located below the upper portion and having a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure having a forward portion pivotably coupled to the upper portion of the base structure for rotation about the first pivot point and a rearward portion located rearward of the forward portion, and wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure having a forward portion pivotably coupled to the lower portion of the base structure for rotation about the second pivot point and a rearward portion located rearwardly of the forward portion, wherein the back support structure is adapted to move between a first position and a second position, and a control link having a first end pivotably coupled to the rearward portion of the seat support structure for rotation about a third pivot point, and a second end pivotably coupled to the rearward portion of the back support structure for rotation about a fourth pivot point.
Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure having a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, and wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to rotate between a first position and a second position, and a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, wherein the control link rotates the seat support structure at a slower rate of rotation than a rate of rotation of the back support structure as the back support structure is rotated between the first and second positions.
Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure pivotably coupled to the first pivot point, wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure pivotably coupled to the second pivot point, wherein the back support structure is adapted to move between a first position and a second position, and wherein the base structure does not move as the back support structure moves between the first and second positions, and a control link pivotably coupled to the rearward portion of the seat support structure for rotation about a third pivot point, and pivotably coupled to the back support structure for rotation about a fourth pivot point, wherein a distance between the first pivot point and the second pivot point is greater than a distance between the third pivot point and the fourth pivot point.
Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure including a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base structure, a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, and wherein the seat support structure is adapted to support a seated user, and a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first full-travel position and a second full-travel position opposite the first full-travel position. The control assembly also comprises a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, wherein the control link is adapted to move between a first position and a second position as the back support structure moves between the first full-travel position and a second full-travel position, the control link includes a longitudinally extending axis that is adapted to form a first angle with a seat support surface of the seat support structure when the control link is in the first position and a second angle with the seat support surface of the seat support structure when the control link is in the second position, the first angle is an acute angle, and wherein the axis of the control link does not rotate substantially beyond perpendicular with the seat support surface as the control link moves between the first and second positions.
Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining an upper portion and a lower portion located below the upper portion, a seat support structure having a forward portion operably coupled to the base structure and a rearward portion located rearwardly of the forward portion, wherein the seat support structure is adapted to support a seated user, and a back support structure having a forward portion operably coupled to the base structure and a rearward portion located rearwardly of the forward portion, wherein the back support structure is adapted to move between a first position and a second position. The control assembly further comprises a control link having a first end operably coupled to the rearward portion of the seat support structure, and a second end operably coupled to the rearward portion of the back support structure, wherein a select one of the base structure and the control link is fixed for rotation with respect to a ground support surface as the back support is moved between the first and second positions.
Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure including a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to be attached to a ground-abutting base support structure, a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, wherein the seat support structure is adapted to support a seated user thereon, and a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first position and a second position. The control assembly also includes a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, and at least one biasing assembly exerting a biasing force torque about the second pivot point that exerts a biasing force against the back support structure that biases the back support structure from the second position towards the first position, wherein the biasing force torque about is adjustable between first and second magnitudes when the back support structure is in the first position, and wherein the second magnitude is greater than the first magnitude.
Yet another aspect of the present invention is to provide a control assembly for a chair comprising a base structure adapted to attach to a ground-abutting base support structure, a seat support structure adapted to couple to the base structure, wherein the seat support structure is adapted to support a seated user thereon, and a back support structure operably coupled to the base structure, wherein the back support structure is adapted to move between a first position and a second position. The control assembly further comprises at least one biasing assembly exerting a biasing force that biases the back support structure from the second position towards the first position, wherein the biasing force is adjustable between first and second magnitudes when the back support structure is in the first position, and wherein the second magnitude is greater than the first magnitude, and an assist feature exerting an assist force on the biasing assembly, thereby reducing the input force required to be applied by the user to adjust the biasing force between the first and second magnitudes.
FIG. 92 is a bottom plan view of the chair assembly as shown in FIG. 86.
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 FIG. 1. 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. Various elements of the embodiments disclosed herein may be described as being operably coupled to one another, which includes elements either directly or indirectly coupled to one another. Further, the term “chair” as utilized herein encompasses various seating arrangements of office chairs, vehicle seating, home seating, stadium seating, theater seating, and the like.
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.
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, stadium seating arrangements, home seating arrangements, theater seating arrangements, and the like.
The seat assembly 16 (FIG. 5A) 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 (FIG. 5B) 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, and a forward edge 45. 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, and 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 having an upper surface 76, and that rests upon the top surface 54 of the seat pan 46 and is cradled within the outer seat shell 40. The seat assembly 16 further includes a fabric seat cover 72 having a forward edge 73, a rearward edge 75, and a pair of side edges 77 extending between the forward edge 73 and rearward edge 75. A spring support assembly 78 (FIGS. 5A and 5B) 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 each linear bearing 96 slidably receives the distal end 90 of a corresponding cantilever spring 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.
The reference numeral 16 a (FIG. 6) generally designates another embodiment of the seat assembly of the present invention. Since the seat assembly 16 a is similar to the previously described seat assembly 16, similar parts appearing in FIG. 5A and FIGS. 6-10, 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 seat assembly 16 a includes a relatively rigid seat support plate 32 a having a forward edge 34 a, a rearward edge 36 a, and a pair of C-shaped guide rails 38 a defining the side edges of the seat support plate 32 a and extending between the forward edge 34 a and the rearward edge 36 a. The seat assembly 16 a further includes a flexibly resilient outer seat shell 40 a (FIGS. 6 and 7) having a pair of upwardly turned side portions 42 a each terminating in a side edge 43 a, a forward edge 45 a, and an upwardly turned rear portion 44 a that terminates in a rear edge 47 a and includes a flap portion 49 a, wherein the side portions 42 a and rear portion 44 a cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40 a is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE) and is molded as a single integral piece. In assembly, described in further detail below, the outer seat shell 40 a is secured and sandwiched between the seat support plate 32 a and a plastic, flexibly resilient seat pan 46 a which is secured to the seat support plate 32 a by a plurality of mechanical fasteners. The seat pan 46 a includes a forward edge 48 a, a rearward edge 50 a, side edges 52 a extending between the forward edge 48 a and the rearward edge 50 a, a top surface 54 a and a bottom surface 56 a that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan 46 a includes a plurality of longitudinally extending slots 58 a extending forwardly from the rearward edge 50 a. The slots 58 a cooperate to define a plurality of fingers 60 a therebetween, each finger 60 a being individually flexibly resilient. The seat pan 46 a further includes a plurality of laterally oriented, elongated apertures 62 a located proximate the forward edge 48 a. The apertures 62 a cooperate to increase the overall flexibility of the seat pan 46 a in the area thereof, and specifically allow a forward portion 64 a of the seat pan 46 a to flex in a vertical direction 66 a with respect to a rearward portion 68 a of the seat pan 46 a, as discussed further below. The seat assembly 16 a further includes a foam cushion member 70 a having an upper surface 76 a, and that rests upon the top surface 54 a of the seat pan 46 a and is cradled within the outer seat shell 40 a. The seat assembly 16 a further includes a fabric seat cover 72 a having a forward edge 73 a, a rearward edge 75 a and a pair of side edges 77 a extending therebetween. The seat assembly 16 a is supported by a spring support assembly 78 a (FIG. 6) that is similar in construction and operation as the previously described spring support assembly 78.
As best illustrated in FIGS. 7 and 8, the flexible resilient seat shell 40 a and the fabric seat cover 72 a cooperate to form an upholstery cover assembly or cover 100 a. Specifically, the side edges 43 a of the seat shell 40 a and the side edges 77 a of the seat cover 72 a, the forward edge 45 a of the seat shell 40 a and the forward edge 73 a of the seat cover 72 a, and the rear edge 47 a of the seat shell 40 a and the rear edge 75 a of the seat cover 72 a are respectively attached to one another to form the cover 100 a and to define an interior space 102 a therein.
The flap portion 49 a of the seat shell 40 a includes a pair of corner edges 104 a each extending along a corner 106 a of the seat shell 40 a located between the rear portion 44 a and respective side portions 42 a, such that the flap portion 49 a is movable between an open position I and a closed position J. In the illustrated example, each corner edge 104 a of the flap portion 49 a includes a plurality of tabs 108 a spaced along the corner edge 104 a and each including an aperture 110 a extending therethrough. The tabs 108 a of the corner edge 104 a are interspaced with a plurality of tabs 112 a spaced along a corner edge 114 a of each side portion 42 a. Each of the tabs 112 a includes an aperture 116 a that extends therethrough. The seat shell 40 a also includes a plurality of integrally-molded coupling tabs 118 a spaced about an inner edge 121 a of the seat shell 40 a and each having a Z-shaped, cross-section configuration.
In assembly, the upholstery cover assembly 100 a (FIG. 9) is constructed from the seat shell 40 a and seat cover 72 a as described above. The seat pan 46 a, the cushion member 70 a and the spring support assembly 78 a are then arranged with respect to one another assembled with the upholstery cover assembly 100 a by positioning the flap 49 a in the open position I, positioning the seat pan 46 a, the cushion member 70 a and spring support assembly 78 a within the interior space 102 a, and then moving the flap 49 a to the closed position J. A pair of quick-connect fasteners 120 a each include a plurality of snap couplers 122 a spaced along the length of an L-shaped body portion 124 a. In assembly, the snap couplers 122 a are extended through the apertures 110 a, 116 a of the tabs 108 a, 112 a, and are snapably received within corresponding apertures 126 a of the seat pan 46 a, thereby securing the corner edges 104 a, 114 a to the seat pan 46 a and the flap portion 49 a in the closed position J.
Further in assembly, the coupling tabs 118 a (FIG. 10) are positioned within corresponding apertures 130 a of the seat pan 46 a, such that the cover assembly 100 a is temporarily secured to the seat pan 46 a, thereby allowing further manipulation of the cover seat assembly 16 a during assembly while maintaining connection and alignment of the cover assembly 100 a with the seat pan 46 a. As used herein, “temporarily securing” is defined as a securing not expected to maintain the securement of the cover assembly 100 a to the seat pan 46 a by itself during normal use of the chair assembly throughout the normal useful life of the chair assembly. The support plate 32 a is then secured to an underside of the seat pan 46 a by a plurality of screws 132 a, thereby sandwiching the coupling tabs 118 a between the support plate 32 a and the seat pan 46 a, and permanently securing the cover assembly 100 a to the seat pan 46 a. As used herein, “permanently securing” is defined as a securing expected to maintain the securement of the cover assembly to the seat pan 46 a during normal use of the chair assembly throughout the normal useful life of the chair assembly.
The reference numeral 16 b (FIG. 11) generally designates another embodiment of the seat assembly. Since the seat assembly 16 b is similar to the previously described seat assemblies 16 and/or seat assembly 16 a, similar parts appearing in FIGS. 5A-10 and FIGS. 11-17 respectively are represented by the same, corresponding reference numeral, except for the suffix “b” in the numerals of the latter. In the illustrated example, the seat assembly 16 b is similar in configuration and construction to the seat assembly 16 and the seat assembly 16 a, with the most notable exception being an alternatively, configured and constructed outer seat shell 40 b and upholstery cover 100 b.
The seat assembly 16 b (FIG. 11) includes a flexibly resilient outer seat shell 40 b having a pair of upwardly turned side portions 42 b each terminating in a side edge 43 b, a forward edge 45 b, and an upwardly turned rear portion 44 b that terminates in a rear edge 47 b, wherein the side portions 42 b and rear portion 44 b cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40 b is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE) and is molded as a single integral piece. In assembly, described in further detail below, the outer seat shell 40 b is secured and sandwiched between the seat support plate 32 b, a plastic, flexibly resilient seat pan 46 b and a plastic, substantially rigid overlay 51 b, each of which is secured to the seat support plate 32 b by a plurality of mechanical fasteners. The overlay 51 b has an upwardly arcuate shape and includes a rear wall 53 b and a pair of forwardly-extending sidewalls 55 b each including a forward-most edge 57 b, and wherein the rear wall 53 b and sidewalls 55 b cooperate to form an uppermost edge 59 b. The seat pan 46 b includes a forward edge 48 b, a rearward edge 50 b, side edges 52 b extending between the forward edge 48 b and the rearward edge 50 b, a top surface 54 b and a bottom surface 56 b that cooperate to form an upwardly disposed generally concave shape.
As best illustrated in FIGS. 12 and 13, the flexible resilient seat shell 40 b, the fabric seat cover 72 b and the overlay 51 b cooperate to form an upholstery cover assembly or cover 100 b. In the illustrated example, the side edges 43 b of the seat shell 40 b and the side edges 77 b of the seat cover 72 b, the forward edge 45 b of the seat shell 40 b and the forward edge 73 b of the seat cover 72 b, and the rear edge 47 b of the seat shell 40 b and the rear edge 75 b of the seat cover 72 b are respectively attached to one another, such that the seat shell 40 b and the fabric seat cover 72 b cooperate with the overlay 51 b to form the cover 100 b and to define an interior space 102 b therein. The seat shell 40 b also includes a plurality of integrally-molded coupling tabs 118 b spaced about an inner edge 121 b of the seat shell 40 b and each having a Z-shaped, cross-section configuration.
In assembly, the seat shell 40 b (FIG. 14) and seat cover 72 b of the upholstery cover 100 b are coupled to one another as described above. As best illustrated in FIGS. 15 and 16, the side portions 42 b of the seat shell 40 b are coupled to the fabric seat cover 72 b so as to define a corner 79 b therebetween. It is noted that use of both the fabric material of the fabric seat cover 72 b and the TPE of the seat shell 40 b provides a sharp and crisp aesthetic corner angle β of 90° or less while simultaneously providing a soft, resilient deformable feel for the user. The seat pan 46 b, the cushion member 70 b and the spring support assembly 78 b are then arranged with respect to one another and positioned within the interior space 102 b of the cover 100 b. The shell 40 b is then secured to the seat pan 46 b for displacement in a lateral direction by a plurality of integral hook-shaped couplers 123 b spaced about the periphery of the shell 40 b and which engage a downwardly-extending trim portion 125 b extending about the side and rear periphery of the seat pan 46 b. The shell 40 b (FIG. 17) further includes a plurality of Z-shaped couplers 127 b integral with the shell 40 b and received within corresponding apertures 129 b of the seat pan 46 b, thereby temporarily securing the shell 40 b to the seat pan 46 b with respect to vertical displacement.
Further in assembly, the overlay 51 b (FIG. 17) includes a plurality of integrally formed, L-shaped hooks 131 b spaced along the sidewalls 55 b and that slidably engage a corresponding plurality of angled couplers 133 b integrally formed with the seat pan 46 b. Specifically, the hooks 131 b engage the couplers 133 b as the overlay 51 b is slid forwardly with respect to the seat pan 46 b. The overlay 51 b is then secured in place by a pair of screws 135 b that extend through corresponding apertures 137 b of the overlay 51 b and are threadably received within corresponding bosses 139 b of the seat pan 46 b, thereby trapping the couplers 127 b within the apertures 129 b. The support plate 32 b is then secured to an underside of the seat pan 46 b by a plurality of screws 132 b, thereby sandwiching a plurality of spaced coupling tabs 141 b integral with the overlay 51 b between the support plate 32 b and the seat pan 46 b, and permanently securing the cover assembly 100 b to the seat pan 46 b. It is noted that the terms “temporarily securing” and “permanently securing” are previously defined herein.
The reference numeral 16 b′ (FIG. 11A) generally designates another embodiment of the seat assembly. Since the seat assembly 16 b′ is similar to the previously described seat assembly 16 b, similar parts appearing in FIG. 11 and FIG. 11A respectively are represented by the same, corresponding reference numeral, except for the suffix “′” in the numerals of the latter. In the illustrated example, the seat assembly 16 b′ is similar in configuration and construction to the seat assembly 16 b, with the most notable exception being an alternatively configured foam cushion member 70 b′. The cushion member 70 b′ includes a first portion 81 b′ and a second portion 83 b′. In assembly, the first portion 81 b′ of the cushion member 70 b′ is positioned over the seat pan 46 b′. The attachment member 84 b′ is secured to an underside of the seat pan 46 b′ by mechanical fasteners such as screws (not shown). The second portion 83 b′ of the cushion member 70 b′ is then wrapped about the front edge 48 b′ of the seat pan 46 b′ and the attachment member 84 b′, and secured to the attachment member 84 b′ by an adhesive. The combination of the seat pan 46 b′, the cushion member 70 b′ and the attachment member 84 b′ is assembled with the seat support plate 32 b′, to which the spring members 88 b′ are previously attached, and the linear bearing 96 b′ are attached thereto.
The back assembly 18 (FIGS. 18-20B) includes a back frame assembly 200 and a back support assembly 202 supported thereby. The back frame assembly 200 is generally comprised of a substantially rigid material such as metal, and includes a laterally extending top frame portion 204, a laterally extending bottom frame portion 206, and a pair of curved side frame portions 208 extending between the top frame portion 204 and the bottom frame portion 206 and cooperating therewith to define an opening 210 having a relatively large upper dimension 212 and a relatively narrow lower dimension 214.
The back assembly 18 further includes a flexibly resilient, plastic back shell 216 having an upper portion 218, a lower portion 220, a pair of side edges 222 extending between the upper portion 218 and a lower portion 220, a forwardly facing surface 224 and a rearwardly facing surface 226, wherein the width of the upper portion 218 is generally greater than the width of the lower portion 220, and the lower portion 220 is downwardly tapered to generally follow the rear elevational configuration of the frame assembly 200. A lower reinforcement member 228 (FIG. 29A) attaches to hooks 230 of lower portion 220 of back shell 216. The reinforcement member 228 includes a plurality of protrusions 232 that engage a plurality of reinforcement ribs 250 of the back shell 216 to prevent side-to-side movement of lower reinforcement member 228 relative to back shell 216, while the reinforcement member 228 pivotably interconnects back control link 236 to lower portion 220 of back shell 216 at pivot point or axis 590, each as described below.
The back shell 216 also includes a plurality of integrally molded, forwardly and upwardly extending hooks 240 (FIG. 21) spaced about the periphery of the upper portion 218 thereof. An intermediate or lumbar portion 242 is located vertically between the upper portion 218 and the lower portion 220 of the back shell 216, and includes a plurality of laterally extending slots 244 that cooperate to form a plurality of laterally extending ribs 246 located therebetween. The slots 244 cooperate to provide additional flexure to the back shell 216 in the location thereof. Pairings of lateral ribs 246 are coupled by vertically extending ribs 248 integrally formed therewith and located at an approximate lateral midpoint thereof. The vertical ribs 248 function to tie the lateral ribs 246 together and reduce vertical spreading therebetween as the back shell 216 is flexed at the intermediate portion 242 thereof when the back assembly 18 is moved from the upright position E to the reclined position F, as described below. The plurality of laterally-spaced reinforcement ribs 250 extend longitudinally along the vertical length of the back shell 216 between the lower portion 220 and the intermediate portion 242. It is noted that the depth of each of the ribs 250 increases along each of the ribs 250 from the intermediate portion 242 toward the lower portion 220, such that the overall rigidity of the back shell 216 increases along the length of the ribs 250.
The back shell 216 (FIGS. 20A and 20B) further includes a pair of rearwardly extending, integrally molded pivot bosses 252 forming part of an upper back pivot assembly 254. The back pivot assembly 254 (FIGS. 22-24B) includes the pivot bosses 252 of the back shell 216, a pair of shroud members 256 that encompass respective pivot bosses 252, a race member 258, and a mechanical fastening assembly 260. Each pivot boss 252 includes a pair of side walls 262 and a rearwardly-facing concave seating surface 264 having a vertically elongated pivot slot 266 extending therethrough. Each shroud member 256 is shaped so as to closely house the corresponding pivot boss 252, and includes a plurality of side walls 268 corresponding to side walls 262, and a rearwardly-facing concave bearing surface 270 that includes a vertically elongated pivot slot 272 extending therethrough, and which is adapted to align with the slot 266 of a corresponding pivot boss 252. The race member 258 includes a center portion 274 extending laterally along and abutting the top frame portion 204 of the back frame assembly 200, and a pair of arcuately-shaped bearing surfaces 276 located at the ends thereof. Specifically, the center portion 274 includes a first portion 278 and a second portion 280, wherein the first portion 278 abuts a front surface of the top frame portion 204 and the second portion 280 abuts a top surface of the top frame portion 204. Each bearing surface 276 includes an aperture 282 extending therethrough and which aligns with a corresponding boss member 284 integral with the back frame assembly 200.
In assembly, the shroud members 256 are positioned about the corresponding pivot bosses 252 of the back shell 216 and operably positioned between the back shell 216 and the race member 258 such that the bearing surface 270 is sandwiched between the seating surface 264 of a corresponding pivot boss 252 and a bearing surface 276. The mechanical fastening assemblies 260 each include a bolt 286 that secures a rounded abutment surface 288 of a bearing washer 290 in sliding engagement with an inner surface 292 of the corresponding pivot boss 252, and threadably engages the corresponding boss member 284 of the back shell 216. In operation, the upper back pivot assembly 254 allows the back support assembly 202 to pivot with respect to the back frame assembly in a direction 294 (FIG. 19) about a pivot axis 296 (FIG. 18).
The back support assembly 202 (FIGS. 20A and 20B) further includes a flexibly resilient comfort member 298 (FIGS. 26A and 26B) attached to the back shell 216 and slidably supporting a lumbar assembly 300. The comfort member 298 includes an upper portion 302, a lower portion 304, a pair of side portions 306, a forward surface 308, and a rearward surface 310, wherein the upper portion 302, the lower portion 304 and the side portions 306 cooperate to form an aperture 312 that receives the lumbar assembly 300 therein. As best illustrated in FIGS. 20B and 25, the comfort member 298 includes a plurality of box-shaped couplers 314 spaced about the periphery of the upper portion 302 and extending rearwardly from the rearward surface 310. Each box-shaped coupler 314 includes a pair of side walls 316 and a top wall 318 that cooperate to form an interior space 320. A bar 322 extends between the side walls 316 and is spaced from the rearward surface 310. In assembly, the comfort member 298 is secured to the back shell 216 by aligning and vertically inserting the hooks 240 (FIG. 23) of the back shell 216 into the interior space 320 of each of the box-shaped couplers 314 until the hooks 240 engage a corresponding bar 322. It is noted that the forward surface 224 of the back shell 216 and the rearward surface 310 of the comfort member 298 are free from holes or apertures proximate the hooks 240 and box-shaped couplers 314, thereby providing a smooth forward surface 308 and increasing the comfort to a seated user.
The comfort member 298 (FIGS. 26A and 26B) includes an integrally molded, longitudinally extending sleeve 324 extending rearwardly from the rearward surface 310 and having a rectangularly-shaped cross-sectional configuration. The lumbar assembly 300 includes a forwardly laterally concave and forwardly vertically convex, flexibly resilient body portion 326, and an integral support portion 328 extending upwardly from the body portion 326. In the illustrated example, the body portion 326 is shaped such that the body portion vertically tapers along the height thereof so as to generally follow the contours and shape of the aperture 312 of the comfort member 298. The support portion 328 is slidably received within the sleeve 324 of the comfort member 298 such that the lumbar assembly 300 is vertically adjustable with respect to the remainder of the back support assembly 202 between a fully lowered position I and a fully raised position J. A pawl member 330 selectively engages a plurality of apertures 332 spaced along the length of support portion 328, thereby releasably securing the lumbar assembly 300 at selected vertical positions between the fully lowered position I and the fully raised position J. The pawl member 330 (FIGS. 27A and 27B) includes a housing portion 334 having engagement tabs 336 located at the ends thereof and rearwardly offset from an outer surface 338 of the housing portion 334. A flexibly resilient finger 340 is centrally disposed within the housing portion 334 and includes a rearwardly-extending pawl 342.
In assembly, the pawl member 330 (FIG. 28) is positioned within an aperture 344 located within the upper portion 302 of the comfort member 298 such that the outer surface 338 of the housing portion 334 of the pawl member 330 is coplanar with the forward surface 308 of the comfort member 298, and such that the engagement tabs 336 of the housing portion 334 abut the rearward surface 310 of the comfort member 298. The support portion 328 of the lumbar assembly 300 is then positioned within the sleeve 324 of the comfort member 298 such that the sleeve 324 is slidable therein and the pawl 342 is selectively engageable with the apertures 332, thereby allowing the user to optimize the position of the lumbar assembly 300 with respect to the overall back support assembly 202. Specifically, the body portion 326 of the lumbar assembly 300 includes a pair of outwardly extending integral handle portions 346 (FIGS. 29A and 29B) each having a C-shaped cross-sectional configuration defining a channel 348 therein that wraps about and guides along the respective side edge 222 of the back shell 216. Alternatively, the lumbar assembly 300 c (FIG. 30) is provided wherein the body portion 326 c and the support portion 328 c are integrally formed, and the handles 346 c are formed separately from the body portion 326 c and are attached thereto. In the alternative embodiment, each handle 346 c includes a pair of blades 350 c received within corresponding pockets 352 c of the body portion 326 c. Each blade 350 c includes a pair of snap tabs 354 c spaced along the length thereof and which snappingly engage an edge of one of a plurality of apertures 356 c within the body portion 326 c.
In operation, a user adjusts the relative vertical position of the lumbar assembly 300, 300 c with respect to the back shell 216 by grasping one or both of the handle portions 346, 346 c and sliding the handle assembly 346, 346 c along the comfort member 298 and the back shell 298 in a vertical direction. A stop tab 358 is integrally formed within a distal end 360 and is offset therefrom so as to engage an end wall of the sleeve 324 of the comfort member 298, thereby limiting the vertical downward travel of the support portion 328 of the lumbar assembly 300 with respect to the sleeve 324 of the comfort member 298.
The back assembly 202 (FIGS. 20A and 20B) further includes a cushion member 362 having an upper portion 364 and a lower portion 366, wherein the lower portion 366 tapers along the vertical length thereof to correspond to the overall shape and taper of the back shell 216 and the comfort member 298.
The back support assembly 202 further includes an upholstery cover assembly 400 (FIG. 31) that houses the comfort member 298, the lumbar support assembly 300 and the cushion member 362 therein. In the illustrated example, the cover assembly 400 comprises a fabric material and includes a front side 402 (FIG. 32A) and a rear side 404 that are sewn together along the respective side edges thereof to form a first pocket 406 having a first interior or inner space 408 that receives the comfort member 298 and the cushion member 362 therein, and a flap portion 410 that is sewn to the rear side 404 and cooperates therewith to form a second pocket 412 having a second interior or inner space 413 (FIG. 32D) that receives the lumbar support assembly 300 therein.
In assembly, the first pocket 406 (FIG. 32A) is formed by attaching the respective side edges of the front side 402 and the rear side 404 to one another such as by sewing or other means suitable for the material for which the cover assembly 400 is comprised, and to define the first interior space 408. An edge of the flap portion 410 is then secured to a lower end of the rear side 404. In the illustrated example, the combination of the back shell 216 and the cushion member 362 are then inserted into the interior space 408 of the first pocket 406 via an aperture 415 of the rear side 404 (FIG. 32B). The upholstery cover assembly 400 is stretched about the cushion member 362 and the comfort member 298, and is secured to the comfort member 298 by a plurality of apertures 420 that receive upwardly extending hook members 424 (FIG. 33) therethrough. Alternatively, the cover assembly 400 may be configured such that apertures 420 are positioned to also receive T-shaped attachment members 422 therethrough. In the illustrated example, the attachment members 422 and the hook members 424 are integrally formed with the comfort member 298. Each attachment member 422 is provided with a T-shaped cross-section or boat-cleat configuration having a first portion 428 extending perpendicularly rearward from within a recess 429 of the rear surface 310 of the comfort member 298, and a pair of second portions 430 located at a distal end of the first portion 428 and extending outwardly therefrom in opposite relation to one another. One of the second portions 430 cooperates with the first portion 428 to form an angled engagement surface 432. The recess 429 defines an edge 434 about the perimeter thereof.
The cover assembly 400 is further secured to the comfort member 298 by a drawstring 436 that extends through a drawstring tunnel 438 of the cover assembly 400, and is secured to the attachment members 422. Specifically, and as best illustrated in FIGS. 34A-34H, each free end of the drawstring 436 is secured to an associated attachment member 422 in a knot-free manner and without the use of a mechanical fastener that is separate from the comfort member 298. In assembly, the drawstring 436 and drawstring tunnel 438 guide about a plurality of guide hooks 439 (FIG. 26B) located about a periphery of and integrally formed with the comfort member 298. The drawstring 436 is wrapped about the associated attachment member 422 such that the tension in the drawstring 436 about the attachment member 422 forces the drawstring 436 against the engagement surface 432 that angles towards the recess 429, thereby forcing a portion of the drawstring 436 into the recess 429 and into engagement with at least a portion of the edge 434 of the recess 429 resulting in an increased frictional engagement between the drawstring 436 and the comfort member 298. FIGS. 35G and 35H illustrate alternative paths that the drawstring 436 may take about the attachment member 422 relative to the steps illustrated in FIGS. 34G and 34H, respectively.
The lumbar assembly 300 (FIG. 32C) is then aligned with the assembly of the cover assembly 400, the cushion member 362 and the comfort member 298 such that the body portion 326 of the lumbar assembly 300 is located near a midsection 414 of the cover assembly 400, and the support portion 328 of the lumbar assembly 300 is coupled with the comfort member 298 as described above. The flap portion 410 (FIG. 32D) is then folded over the lumbar assembly 300, thereby creating a second pocket 412 having an interior space 413. A distally located edge 442 of the flap portion 410 is attached to the comfort member 298 by a plurality of apertures 444 within the flap portion 410 that receive the hooks 424 therethrough. The distal edge 442 may also be sewn to the rear side 404 of the cover assembly 400. In the illustrated example, the side edges 446 of the flap portion 410 are not attached to the remainder of the cover assembly 400, such that the side edges 446 cooperate with the remainder of the cover assembly 400 to form slots 448 through which the handle portions 346 of the lumbar assembly 300 extend. The second pocket 412 is configured such that the lumbar assembly 300 is vertically adjustable therein. The assembly of the cover assembly 400, the cushion member 362, the comfort member 298 and the lumbar assembly 300 are then attached to the back shell 216.
The reference numeral 18 d (FIG. 36) generally designates an alternative embodiment of the back assembly. Since back assembly 18 d is similar to the previously described back assembly 18, similar parts appearing in FIGS. 20A and 20B and FIGS. 36-41 are represented respectively by the same corresponding reference numeral, except for the suffix “d” in the numerals of the latter. The back assembly 18 d includes a back frame assembly 200 d, a back shell 216 d, and an upholstery cover assembly 400 d. In the illustrated example, the back shell 216 d includes a substantially flexible outer peripheral portion 450 d (FIGS. 37 and 38) and a substantially less flexible rear portion 452 d to which the peripheral portion 450 d is attached. The rear portion 452 d includes a plurality of laterally extending, vertically spaced slots 454 d that cooperate to define slats 456 d therebetween. The peripheral portion 450 d and the rear portion 452 d cooperate to form an outwardly facing opening 458 d extending about a periphery of the back shell 216 d. The rear portion 452 d includes a plurality of ribs 460 d spaced about the opening 458 d and are utilized to secure the cover assembly 400 d to the back shell 216 d as described below.
The cover assembly 400 d includes a fabric cover 462 d and a stay-member 464 d extending about a peripheral edge 466 d of the fabric cover 462 d. The fabric cover 462 d includes a front surface 468 d and a rear surface 470 d and preferably comprises a material flexible in at least one of a longitudinal direction and a lateral direction. As best illustrated in FIG. 39, the stay member 464 d is ring-shaped and includes a plurality of widened portions 472 d each having a rectangularly-shaped cross-sectional configuration interspaced with a plurality of narrowed corner portions 474 d each having a circularly-shaped cross-sectional configuration. Each of the widened portions 472 d include a plurality of apertures 476 d spaced along the length thereof and adapted to engage with the ribs 460 d of the back shell 216 d, as described below. The stay member 464 d is comprised of a relatively flexible plastic such that the stay member 464 d may be turned inside-out, as illustrated in FIG. 40.
In assembly, the stay member 464 d is secured to the rear surface 470 d of the cover 462 d such that the cover 462 d is fixed for rotation with the widened portions 472 d, and such that the cover 462 d is not fixed for rotation with the narrowed corner portions 474 d along a line tangential to a longitudinal axis of the narrowed corner portions 474 d. In the present example, the stay member 464 d (FIG. 41) is sewn about the peripheral edge 466 d of the cover 462 d by a stitch pattern that extends through the widened portions 472 d and about the narrowed corner portions 474 d. The cover assembly 400 d of the cover 462 d and the stay member 464 d are aligned with the back shell 216 d, and the peripheral edge 466 d of the cover 462 d is wrapped about the back shell 216 d such that the stay member 464 d is turned inside-out. The stay member 464 d is then inserted into the opening or groove 458 d, such that the tension of the fabric cover 462 d being stretched about the back shell 216 d causes the stay member 464 d to remain positively engaged within the groove 458 d. The ribs 460 d of the back shell 216 d engage the corresponding apertures 476 d of the stay member 464 d, thereby further securing the stay member 464 d within the groove 458 d. It is noted that the stitch pattern attaching the cover 462 d to the stay member 464 d allows the narrowed corner portions 474 d of the stay member 464 d to rotate freely with respect to the cover 462 d, thereby reducing the occurrence of aesthetic anomalies near the corners of the cover 462 d, such as bunching or over-stretch of a given fabric pattern.
The seat assembly 16 and the back assembly 18 are operably coupled to and controlled by the control assembly 14 (FIG. 42) and a control input assembly 500. The control assembly 14 (FIGS. 43-45) includes a housing or base structure or ground structure 502 that includes a front wall 504, a rear wall 506, a pair of side walls 508 and a bottom wall 510 integrally formed with one another and that cooperate to form an upwardly opening interior space 512. The bottom wall 510 includes an aperture 514 centrally disposed therein, as described below. The base structure 502 further defines an upper and forward pivot point 516, a lower and forward pivot point 518, and an upper and rearward pivot point 540, wherein the control assembly 14 further includes a seat support structure 522 that supports the seat assembly 16. In the illustrated example, the seat support structure 522 has a generally U-shaped plan form configuration that includes a pair of forwardly extending arm portions 524 each including a forwardly located pivot aperture 526 pivotably secured to the base structure 502 by a pivot shaft 528 for pivoting movement about the upper and forward pivot point 516. The seat support structure 522 further includes a rear portion 530 extending laterally between the arm portions 524 and cooperating therewith to form an interior space 532 within which the base structure 502 is received. The rear portion 530 includes a pair of rearwardly extending arm mounting portions 534 to which the arm assemblies 20 are attached as described below. The seat support structure 522 further includes a control input assembly mounting portion 536 to which the control input assembly 500 is mounted. The seat support structure 522 further includes a pair of bushing assemblies 538 that cooperate to define the pivot point 540.

References: Application No. 61
 Application No. 61
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 application No. 29
 application No. 29