Patent Document

BACKGROUND OF THE INVENTION  
       [0001]     1. Technical Field  
         [0002]     The invention relates to load support structures. In particular, the invention relates to suspended pixelated seating structures.  
         [0003]     2. Related Art  
         [0004]     Most people spend a significant amount of time sitting each day. Inadequate support can result in reduced productivity, body fatigue, or even adverse health conditions such as chronic back pain. Extensive resources have been devoted to research and development of chairs, benches, mattresses, sofas, and other load support structures.  
         [0005]     In the past, for example, chairs have encompassed designs ranging from cushions to more complex combinations of individual load bearing elements. These past designs have improved the general comfort level provided by seating structures, including providing form fitting comfort for a user&#39;s general body shape. Some discomfort, however, may still arise even from the improved seating structures. For example, a seating structure, though tuned to conform to a wide variety of general body shapes, may resist conforming to a protruding wallet, butt bone, or other local irregularity in body shape. This may result in discomfort as the seating structure presses the wallet or other body shape irregularity up into the seated person&#39;s backside.  
         [0006]     Thus, while some progress has been made in providing comfortable seating structures, there remains a need for improved seating structures tuned to fit and conform to a wide range of body shapes and sizes.  
       SUMMARY  
       [0007]     A suspended pixelated seating structure provides comfortable and durable seating support. The suspended pixelated seating structure includes multiple cooperative layers to maximize global comfort and support while enhancing adaptation to localized irregularities in body shape. The cooperative layers each use independent elements such as pixels, springs, support rails, and other elements to provide significant comfort for localized protrusions or irregularities, as well as for general or more uniform characteristics, in an applied load, such as that applied when a person sits in a chair. The suspended pixelated seating structure also uses aligned material to provide a flexible yet durable seating structure. In this manner each portion of the suspended pixelated seating structure may independently conform to and support non-uniform shapes, sizes, weights, and other load characteristics.  
         [0008]     The suspended pixelated seating structure may include a macro compliance layer, a micro compliance layer, and a load support layer. The macro compliance layer provides controlled deflection of the seating structure upon application of a load. The macro compliance layer includes multiple primary support rails which also support the micro compliance layer. The macro compliance layer may also include multiple tensile expansion members which may include an aligned material to facilitate deflection of the macro compliance layer when a load is imposed. The macro compliance layer further includes multiple expansion control strands connected between the multiple primary support rails. As the tensile expansion members facilitate deflection of the macro compliance layer, the expansion control strands may inhibit excess deflection. Accordingly, the suspended pixelated seating structure is tuned to be highly sensitive and conform to very light loads, while providing controlled deflection for heavier loads.  
         [0009]     The micro compliance layer facilitates added and independent deflection upon application of a load to the suspended pixelated seating structure. The micro compliance layer includes multiple spring elements supported by the multiple primary support rails. The multiple spring elements each include a top and a deflection member. Each of the multiple spring elements may independently deflect under a load based upon a variety of factors, including the spring type, relative position of the spring element within the suspended pixelated seating structure, spring material, spring dimensions, connection type to other elements of the suspended pixelated seating structure, and other factors.  
         [0010]     The load support layer may be the layer upon which a load is applied. The load support layer includes multiple pixels positioned above the multiple spring elements. The multiple pixels contact with the tops of the multiple spring elements. Like the multiple spring elements, the multiple pixels may also provide a response to an applied load independent of the responses of adjacent pixel.  
         [0011]     Accordingly, the suspended pixelated seating structure includes cooperative yet independent layers, with each layer including cooperative yet independent elements, to provide maximized global support and comfort to an applied load while also adapting to and supporting localized load irregularities. Further, the load support independence provided by the suspended pixelated seating structure allows specific regions to adapt to any load irregularity without substantially affecting the load support provided by adjacent regions.  
         [0012]     Other systems, methods, features and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.  
         [0014]      FIG. 1  shows a portion of a suspended pixelated seating structure.  
         [0015]      FIG. 2  shows a broader view of the suspended pixelated seating structure shown in  FIG. 1 .  
         [0016]      FIG. 3  shows the portion of the macro compliance layer shown in  FIG. 1 .  
         [0017]      FIG. 4  shows a support structure frame attachment including multiple tensile expansion members.  
         [0018]      FIG. 5  shows a four sided tower spring.  
         [0019]      FIG. 6  shows the four sided tower spring shown in  FIG. 5  deflecting under a load.  
         [0020]      FIG. 7  shows a plot of the approximate spring rate of the four sided tower spring.  
         [0021]      FIG. 8  shows a top view of the macro and micro compliance layers of a suspended pixelated seating structure including multiple tensile expansion members defined along the multiple primary support rails.  
         [0022]      FIG. 9  shows a coil spring.  
         [0023]      FIG. 10  shows a portion of a suspended pixelated seating structure where the multiple spring elements are multiple coil springs.  
         [0024]      FIG. 11  shows a broader view of the suspended pixelated seating structure shown in  FIG. 10 .  
         [0025]      FIG. 12  shows a squiggle spring connected between adjacent primary support rails and adjacent secondary support rails.  
         [0026]      FIG. 13  shows the top view of a portion of a suspended pixelated seating structure where the multiple spring elements are squiggle springs.  
         [0027]      FIG. 14  shows an angled top view of the portion of the suspended pixelated seating structure shown in  FIG. 13 .  
         [0028]      FIG. 15  shows a portion of a suspended pixelated seating structure where the micro compliance layer includes two sided tower springs.  
         [0029]      FIG. 16  shows a broader view of the portion of the suspended pixelated seating structure shown in  FIG. 15 .  
         [0030]      FIG. 17  shows a top view of the suspended pixelated seating structure shown in  FIG. 16 .  
         [0031]      FIG. 18  shows a side view of the suspended pixelated seating structure shown in  FIG. 16 .  
         [0032]      FIG. 19  shows a portion of a load support layer  1900  that may be used in a suspended pixelated seating structure.  
         [0033]      FIG. 20  shows a side view of the load support layer shown in  FIG. 19 .  
         [0034]      FIG. 21  shows a load support layer including multiple rectangular pixels interconnected at their sides via multiple pixel connectors.  
         [0035]      FIG. 22  shows a side view of the load support layer shown in  FIG. 21 .  
         [0036]      FIG. 23  shows a load support layer including multiple contoured pixels.  
         [0037]      FIG. 24  shows an angled view of the load support layer shown in  FIG. 23 .  
         [0038]      FIG. 25  shows a side view of the load support layer shown in  FIGS. 23 and 24 .  
         [0039]      FIG. 26  shows a close up of one of the contoured pixels shown in  FIGS. 23 and 24 .  
         [0040]      FIG. 27  shows a side view of a suspended pixelated seating structure including a bolstering member. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0041]     The suspended pixelated seating structure generally refers to an assembly of multiple (e.g., three) cooperative layers for implementation in or as a load bearing structure, such as in a chair, bed, bench, or other load bearing structures. The cooperative layers include multiple elements, including multiple independent elements, to maximize the support and comfort provided. The extent of the independence exhibited by the multiple elements may depend upon, or be tuned according to, individual characteristics of each element, the connection type used to interconnect the multiple elements, or other the structural or design characteristics of the suspended pixelated seating structure. The multiple elements described below may be individually designed, positioned, or otherwise configured to suit the load support needs for a particular individual or application. In addition, the dimensions discussed below with reference to the various multiple elements are examples only and may vary widely depending upon the particular desired implementation and on the factors noted below.  
         [0042]      FIG. 1  shows a portion of a suspended pixelated seating structure  100 . The suspended pixelated seating structure  100  includes a macro compliance layer  102 , a micro support layer  104 , and a load support layer  106 .  
         [0043]     The macro compliance layer  102  includes multiple primary support rails  108 , multiple expansion control strands  110 , and a support structure frame attachment  112 . Each multiple primary support rail  108  may also include multiple secondary support rails  114  extending from the primary support rail  108 .  
         [0044]     The support structure frame attachment  112  may include a frame attachment rail  116  and multiple frame connectors  118  defined along the frame attachment rail  116 . The support structure frame attachment  112  also includes multiple rail attachment nodes  120  and multiple tensile expansion members  122  connected between the multiple frame connectors  118  and multiple rail attachment nodes  120 .  
         [0045]     The micro compliance layer  104  includes multiple spring elements  124  above (e.g., supported by or resting on) the multiple primary support rails  108 . Each of the multiple spring elements  124  includes a top  126 , a deflectable member  128 , and multiple spring attachment members  130 . In  FIG. 1  the multiple spring elements  124  are four sided tower springs. The multiple spring elements  124  may alternatively include a variety of spring types, as is discussed below.  
         [0046]     The load support layer  106  includes multiple pixels  132 . Each of the multiple pixels  132  includes an upper surface  134  and a lower surface. The lower surface of each of the multiple pixels  132  may include a stem  136  which contacts with the top  126  of at least one of the spring elements  124 . The multiple pixels  132  may also include one or more openings  138  defined within the multiple pixels  132 . The openings  138  may increase the flexibility of the multiple pixels  132 . The openings  138  may also be positioned and/or defined to function as ventilation elements to provide aeration to the suspended pixelated seating structure  100 . The openings  138  may also be positioned and designed for aesthetic appeal. The multiple pixels  132  may be interconnected with multiple pixel connectors  148 .  
         [0047]     The macro compliance layer  102  connects to a support structure frame via the support structure frame attachment  112 . The support structure frame may be the frame of chair, bench, bed, or other load support structure. As described in this application, the macro compliance layer  102  may include the support structure frame attachment  112 . In other examples, the support structure frame attachment  112  may be separate from the macro compliance layer  102 . For example, the support structure frame may alternatively include the support structure frame attachment  112 . In yet other examples, the suspended pixelated seating structure  100  may omit the support structure frame attachment  112 .  FIG. 4  shows a close-up view of the support structure frame attachment  112 .  
         [0048]     The frame connectors  118  may define frame attachment openings  140  for connection to the support structure frame. The frame connectors  118  may alternatively include cantilevered elements for securing the support structure frame attachment  112  to openings defined in the support structure frame. As another alternative, the support structure frame attachment  112  may omit the frame attachment rail  116 . In this example, the frame connectors  118  may be independent of the adjacent frame connectors  118 , except through their respective connections to the support structure frame. The support structure frame attachment  112  may connect to the support structure frame via a snap fit connection, an integral molding, or other connection methods.  
         [0049]     The support structure frame attachment  112  also includes the multiple tensile expansion members  122 . The multiple tensile expansion members  122  may connect between the frame attachment rail  116  and the rail attachment nodes  120 . The multiple tensile expansion members  122  are flexible elements with high tensile strength, allowing the macro compliance layer  102  to effectively respond under light loads while remaining secure under heavier loads. The multiple tensile expansion members  122  include aligned material. The material may be the flexible material used to injection mold the support structure frame attachment, i.e., TPE&#39;s, PP&#39;s, TPU&#39;s, or other flexible materials. The material may be aligned using a variety of methods including compression and/or tension aligning methods.  
         [0050]     The multiple tensile expansion members  122  connect to multiple ends  142  of the multiple primary support rails  108  via the rail attachment nodes  120 . The multiple ends  142  of the multiple primary support rails  108  may be cantilevered ends  142 . The rail attachment nodes  120  may define an opening  146  for connection to the cantilevered ends  142  of each multiple primary support rail  108 . This connection may include a snap-fit connection, integrally molding the multiple tensile expansion members  122  to the ends  142  of the primary support rails  108 , or other connection methods.  
         [0051]     The support structure frame attachment  112  in  FIG. 1  may be injection molded from a flexible material such as a thermal plastic elastomer (TPE), including Arnitel EM400 or 460, a polypropylene (PP), a thermoplastic polyurethane (TPU), or other soft, flexible materials. The support structure frame attachment  112  may be positioned around all or a portion of the perimeter of the macro compliance layer  102 . Accordingly, the suspended pixelated seating structure  100  is suspended from the support structure frame.  
         [0052]     The multiple primary support rails  108 , multiple secondary support rails  114 , and multiple expansion control strands  110  shown in  FIG. 1  may be injection molded from a stiff material, such as glass fiber-reinforced polybutylene terephthalate (GF-PBT), glass fiber-reinforced polyamide (GF-PA), or other firm materials.  
         [0053]     The multiple primary support rails  108  shown in  FIG. 1  include multiple shafts  144  having four sides and the multiple ends  142 . The multiple primary support rails  108 , however, may include alternative geometries. For example, each of the multiple primary support rails  108  may include a cylindrical shaft, as shown in  FIGS. 11 and 12 . Alternatively, the multiple primary support rails  108  may include a series of nodes and/or tensile expansion members defined along the primary support rails  108 , as shown in  FIG. 10 .  
         [0054]     As described above, the ends  142  of the multiple primary support rails  108  may be cantilevered ends  142 , as shown in  FIG. 4 , for attachment to the support structure frame attachment  112 . Alternatively, the ends  142  of the primary support rails  108  may define an opening for attachment to the multiple tensile expansion members  122 . As another alternative, the ends  142  may be integrally molded to the support structure frame attachment  112 . Further, the ends  142  of the multiple primary support rails  108  may instead connect to the support structure frame. As yet another alternative, the support structure frame attachment  112  may be replaced by frame springs such that the multiple primary support rails  108  are suspended from the support structure frame via the frame springs. The frame springs may be conventional springs or other spring types.  
         [0055]      FIG. 1  shows the multiple tensile expansion members  122  extending from and attaching to the ends  142  of the multiple primary support rails  108 . In other examples, including in those described below, the multiple tensile expansion members  122  may alternatively be defined along the multiple primary support rails  108  and/or along the multiple secondary support rails  114 . In such examples the ends  142  of the multiple primary and/or secondary support rails  108  and  114  may connect to the support structure frame attachment  112 . Where the suspended pixelated seating structure  100  defines multiple tensile expansion members  122  along the multiple primary and/or secondary support rails  108  and  114 , the macro compliance layer  102 , including the multiple primary and secondary support rails  108  and  114  and multiple expansion control strands  110 , may be injection molded from the softer, flexible materials used to form the support structure frame attachment  112  discussed above.  
         [0056]     Multiple tensile expansion members  122  defined along the multiple primary and/or secondary support rails  108  and  114  may be aligned using a variety of methods including compression and/or tension aligning methods. For example, in examples where the multiple tensile expansion members  122  are defined along the multiple primary and secondary support rails  108  and  114 , the aligned portions defined along the multiple primary support rails  108  may be compression aligned while the aligned portion defined along the multiple secondary support rails  114  may be tension aligned, or visa versa.  
         [0057]     The alternative suspended pixelated seating structures discussed below define the multiple tensile expansion members  122  along the multiple primary support rails  108 . In the examples discussed below, the multiple tensile expansion members  122  may be defined along substantially the entire length of the multiple primary support rails  108  or as discrete aligned segments along the length of the multiple primary support rails  108 . In each alternative example below, the multiple tensile expansion members  122  may alternatively be included in the support structure frame attachment  112  in the manner shown in  FIG. 1 .  
         [0058]     As the macro compliance layer  102  deflects downward when a load is applied to the suspended pixelated seating structure  100 , the multiple primary support rails  108  may spread apart from each other to facilitate adaptation to the load. The multiple expansion control strands  110  provide for controlled separation of the multiple primary support rails  108  to prevent the macro compliance layer  102  from excess separation, such as when a heavier load is applied. The multiple expansion control strands  110  may be non-linear, as shown in  FIG. 1 . In this manner, the multiple expansion control strands  110  can provide slack for the separation of the multiple primary support rails  108 .  
         [0059]     The amount of slack provided by the multiple expansion control strands  110  may be tuned in a variety of ways. For example, the number and/or degree of bends in the multiple expansion control strands  110  may affect the amount of slack provided. In addition, varying the type of material used to form the multiple expansion control strands  110  may affect the amount of slack. The multiple expansion control strands  110  may alternatively be linear, as shown, for example, in  FIG. 15 .  
         [0060]      FIG. 1  shows the multiple expansion control strands  110  connected between the ends  142  of each adjacent primary support rail  108 . Alternatively, the multiple expansion control strands  110  may connect between less than all adjacent primary support rails  108 . For example, the multiple expansion control strands  110  may connect between every other set of adjacent primary support rails  108 . The multiple expansion control strands  110  may also connect between adjacent primary support rails  108  at multiple positions along the length of the multiple primary support rails  108 , as shown, for example, in  FIG. 10 .  
         [0061]     The multiple secondary support rails  114  may provide further support to the suspended pixelated seating structure  100 . In particular, the multiple primary and secondary support rails  108  and  114  support the multiple spring elements  124  of the micro compliance layer  104 . The multiple spring elements  124  may be secured on adjacent primary support rails  108  and on adjacent secondary support rails  114  via the spring attachment members  130 . The spring attachment members  130  may be integrally molded to the primary and secondary support rails  108  and  114 , may attach via a snap-fit connection, or may be secured using other methods.  
         [0062]     The macro compliance layer  102  may or not be pre-loaded. For example, prior to connecting the macro compliance layer  102  may initially be formed, such as through the injection molding process, with a shorter length than is needed secure the macro compliance layer  102  to the support structure frame. Before securing the macro compliance layer  102  to the support structure frame, the macro compliance layer  102  may be stretched or compressed to several times its original length. As the macro compliance layer  102  settles down after being stretched, the macro compliance layer  102  may be secured to the support structure frame when the macro compliance layer  102  settles to a length that matches the width of the support structure frame.  
         [0063]     As another alternative, the macro compliance layer  102  may settle down and then be repeatedly re-stretched until the settled down length of the macro compliance layer  102  matches the width of the support structure frame. The macro compliance layer may be pre-loaded in multiple directions, such as along its length and/or width. In addition, different pre-loads may be applied to different regions of the macro compliance layer  102 . Applying different pre-loads according to region may be done in a variety of ways, such as by varying the amount of stretching or compressing at different regions and/or varying the thickness of different regions.  
         [0064]      FIG. 1  shows an example of the micro compliance layer  104  in which the multiple spring elements  124  are four sided tower springs. The four sided tower spring is described below and shown in  FIGS. 5 and 6 . The multiple spring elements  124  shown in  FIG. 1  have an approximate length and width of 40 mm×40 mm and an approximate height of 16 mm. However, each of the multiple spring elements  124  may include alternative dimensions according to a variety of factors including the spring element&#39;s  124  relative location in the suspended pixelated seating structure  100 , the needs of a specific application, or according to a number of other considerations. For example, the height may be varied to provide a three-dimensional contour to the suspended pixelated seating structure  100 , providing a dish-like appearance to the suspended pixelated seating structure  100 . In this example, the height of the multiple springs elements  124  positioned in the center portion of the micro compliance layer  104  may be less than the height of the multiple spring elements  124  positioned at the outer portions of the micro compliance layer  104 , with a gradual or other type of increase in height in the multiple spring elements  124  between the center and outer portions of the micro compliance layer  104 .  
         [0065]     Alternatively, the micro compliance layer  104  may include a variety of other spring types. Examples of other spring types, as well as how they may be implemented in a suspended pixelated seating structure, are described below and shown in  FIGS. 9-18 . The spring types used in the micro compliance layer  104  may include alternative orientations. For example, the spring types may be oriented upside-down, relative their orientation described in this application. In this example, the portion of the spring described in this application as the top would be oriented towards and connect to the macro compliance layer. Further, in this example the deflectable members may connect to the load support layer. The deflectable members may connect to the load support layer via multiple spring attachment members However, the examples discussed in this application do not constitute an exhaustive list of the spring types, or possible orientations of spring types, that may be used to form the micro compliance layer  104 . The spring elements  124  may exhibit a range of spring rates, including linear, non-linear decreasing, non-linear increasing, or constant rate spring rates.  FIG. 7  shows a plot of the approximate non-linear decreasing spring rate for the four side tower spring  124 .  
         [0066]     The micro support layer  104  connects on the macro compliance layer  102 . In particular, the spring attachment members  130  connect on the multiple primary support rails  108  and in some examples, on the multiple secondary support rails  114 . This connection may be an integral molding, a snap fit connection, or other connection method. The multiple spring elements  124  may be injection molded from a TPE, such as Arnitel EM460, EM550, or EL630, a TPU, a PP, or from other flexible materials. The multiple spring elements  124  may be injection molded individually or as a sheet of multiple spring elements  124 .  
         [0067]     As the micro compliance layer  104  includes multiple substantially independent deflectable elements, i.e., the multiple spring elements  124 , adjacent portions of the micro compliance layer  104  may exhibit substantially independent responses to a load. In this manner, the suspended pixelated seating structure  100  not only deflects and conforms under the “macro” characteristics of the applied load, but also provides individual, adaptable deflection to “micro” characteristics of the applied load.  
         [0068]     The micro compliance layer  104  may also be tuned to exhibit varying regional responses in any particular zone, area, or portion of the support structure to provide specific support for specific parts of an applied load. The regional response zones may differ in stiffness or any other load support characteristic, for example. Certain portions of the suspended pixelated seating structure  100  may be tuned with different deflection characteristics. One or more individual pixels which form a regional response zone, for example, may be specifically designed to a selected stiffness for any particular portion of the body. These different regions of the suspended pixelated seating structure  100  may be tuned in a variety of ways. As described in more detail below with reference to the load support layer  106 , variation in the spacing between the lower surface of each pixel  132  and the macro compliance layer  102  (referring to the spacing measured when no load is present) may vary the amount of deflection exhibited under a load. The regional deflection characteristics of the suspended pixelated seating structure  100  may be tuned using other methods as well, including using different materials, spring types, thicknesses, geometries, or other spring characteristics for the multiple spring elements  124  depending on their relative locations in the suspended pixelated seating structure  100 .  
         [0069]     The load support layer  106  connects to the micro compliance layer  104 . The lower surface of each pixel  132  is secured to the top  126  of a corresponding spring element  124 . This connection may be an integral molding, a snap fit connection, or other connection method. The lower surface may connect to the top  126  of the spring element  124 , or may include a stem  136  or other extension for resting upon or connecting to the spring elements  124 . The top  126  of each spring element  124  may define an opening for receiving the stem  136  of the corresponding pixel. Alternatively, the top  126  of each multiple spring element  124 , or of any other type of spring element described below, may include a stem or post for connecting to an opening defined in the corresponding pixel.  
         [0070]     Whether the lower surface of each pixel  132  includes a stem  136  may depend on the type of spring element  124  used, a predetermined spring deflection level, and/or other characteristics or specifications. When a load presses down on the load support layer  106 , the multiple pixels  132  press down on the tops  126  of the multiple spring elements  124 . In response, the multiple spring elements  124  deflect downward to accommodate the load. As the multiple spring elements  124  deflect downward, the lower surfaces of the multiple pixels  132  move toward the macro compliance layer  102 . One or more multiple spring elements  124  may deflect far enough such that the lower surfaces of the corresponding pixels  132  abut on top of the macro compliance layer  102 . In this instance, the spring element  124  corresponding to the pixel  132  whose lower surface abuts with the macro compliance layer  102  may not deflect further, relative to itself.  
         [0071]     The amount of deflection exhibited by the spring element  124  before the lower surface of the corresponding pixel  132  abuts on top of the macro compliance layer  102  is the spring deflection level. Relative to ground, however, the multiple spring elements  124  may deflect further in that the micro compliance layer  104  may deflect downward under a load as the macro compliance  102  layer deflects under a load. As such, the multiple spring elements  124  may individually deflect under a load according to the spring deflection level, and may also, as part of the micro compliance layer  104 , deflect further as the micro compliance layer  104  bends downward under a load.  
         [0072]     The spring element  124  may stop deflecting under a load when the lower surface of the pixel  132  abuts on top of some portion of the micro compliance layer  104  such as on top of the multiple spring attachment members  130 . This may be the case where the spring attachment members  130  are positioned above the macro compliance layer  102 , such as in the suspended pixelated seating structure  100  shown in  FIG. 1 .  
         [0073]     The spring deflection level may be determined before manufacture and designed into the suspended pixelated seating structure  100 . For example, the suspended pixelated seating structure may be tuned to exhibit an approximately 25 mm of spring deflection level. In other words, the suspended pixelated seating structure  100  may be designed to allow the multiple spring elements  124  to deflect up to approximately 25 mm. Thus where the micro compliance layer  104  includes spring elements  124  of 16 mm height (i.e., the distance between the top of the macro compliance layer  102  and the top  126  of the spring element  124 ), the lower surfaces of the multiple pixels  132  may include a 9 mm stem. As another example, where the micro compliance layer  104  includes spring elements  124  of 25 mm height, the lower surfaces of the multiple pixels  132  may omit stems; but may rather connect to the tops  126  of the multiple spring elements  124 . As explained above, the height of each spring element  124  may vary according to a number of factors, including its relative position within the suspended pixelated seating structure  100 .  
         [0074]     The multiple pixels  132  may be interconnected with multiple pixel connectors  148 . The L-shaped element shown in  FIG. 1  is a cross sectional portion of a pixel connector  148 . Accordingly,  FIG. 1  shows the multiple pixels  132  interconnected at their sides via the multiple pixel connectors  148 . The load support layer  106  may include a variety of pixel connectors  148 , such as planar or non-planar connectors, recessed connectors, bridged connectors, or other elements for interconnecting the multiple pixels  132 , as described below. The multiple pixel connectors  148  may be positioned at a variety of locations with reference to the multiple pixels  132 . For example, the multiple pixels connectors  148  may be positioned at the corners, sides, or other positions in relation to the multiple pixels  132 . The multiple pixel connectors  148  provide an increased degree of independence as between adjacent pixels  132 , as well as enhanced flexibility to the load support layer  106 . For example, the multiple pixel connectors  148  may allow for flexible downward deflection, as well as for individual pixels  132  to move or rotate laterally with a significant amount of independence.  
         [0075]     The multiple pixels  132  may define openings  138  within the pixels  132  for added deflection of the suspended pixelated seating structure  100 . The openings  138  allow for added flexibility and adaptation by the multiple pixels  132  when placed under a load. The openings  138  may also be defined within the multiple pixels  132  to enhance the aesthetic characteristics of the suspended pixelated seating structure  100 .  
         [0076]     The load support layer  106  may be injection molded from a flexible material such as a TPE, PP, TPU, or other flexible materials. In particular, the load support layer  106  may be formed from independently manufactured pixels  132 , or may be injection molded as a sheet of multiple pixels  132 . The load support layer  106  may also connect to a support structure via support structure connection elements, as is described below and shown, for example, in  FIG. 23 .  
         [0077]     When under a load, the load may contact with and press down on the load support layer  106 . Alternatively, the suspended pixelated seating structure  100  may also include a seat covering layer secured above the load support layer  106 . The seat covering layer may include a cushion, fabric, leather, or other seat covering materials. The seat covering layer may provide enhanced comfort and/or aesthetics to the suspended pixelated seating structure  100 .  
         [0078]      FIG. 2  shows a broader view of the suspended pixelated seating structure  100  shown in  FIG. 1 . While  FIG. 2  shows a rectangular suspended pixelated seating structure  100 , the suspended pixelated seating structure  100  may include alternative shapes, including a circular shape. The support structure frame attachment  112  may be positioned around all or a portion of the perimeter of the suspended pixelated seating structure  100 .  
         [0079]      FIG. 3  shows a portion of the macro compliance layer  102 . As noted above in connection with  FIG. 1 , the macro compliance layer  102  includes the multiple primary support rails  108 , multiple secondary support rails  114 , and multiple expansion control strands  110 . The multiple primary support rails  108  include multiple cantilevered ends  142  for attachment to the support structure frame attachment.  
         [0080]     The multiple primary support rails  108  are aligned substantially in parallel, but may adhere to other alignments depending on the desired implementation. The multiple primary support rails  108  may be of equal length, or of varying lengths. For example, the length of the multiple primary support rails  108  may vary where the suspended pixelated seating structure  100  is designed for attachment to a circular support structure.  
         [0081]     The multiple secondary support rails  114  extend between adjacent primary support rails  108 , but contact with one primary support rail  108 . Alternatively, the multiple secondary support rails  114  may vary in length, including extending the entire distance between and contacting adjacent primary support rails  108 . As another alternative, the suspended pixelated seating structure  100  may omit secondary support rails  114 . The secondary support rails  114  may be linear or non-linear. Non-linear secondary support rails may function as expansion control strands to provide for controlled separation of the multiple primary support rails  108  when a load is imposed.  
         [0082]      FIG. 4  shows the support structure frame attachment  112 . As described above, the support structure frame attachment  112  includes the frame attachment rail  116 , the multiple frame connectors  118 , and the multiple rail attachment nodes  120 . The support structure frame attachment  112  also includes the multiple tensile expansion members  122  connected between the multiple rail attachment nodes  120  and the frame connectors  118 .  FIG. 4  shows circular openings  140  and  146  defined within the multiple frame connectors  118  and multiple rail attachment nodes  120  respectively. These openings  140  and  146  may alternatively include other geometrically shaped openings.  
         [0083]     As described above, the macro compliance  102  layer may include the support structure frame attachment  112  for connection to the support structure frame; but may alternatively omit the support structure frame attachment  112  in connecting to the support structure frame. Further, the support structure frame attachment  112  may omit the multiple tensile expansion members  122 , which may alternatively be defined, for example, along the multiple primary support rails  108 .  
         [0084]      FIG. 5  shows a four sided tower spring  500 . The four sided tower spring  500  includes a top  502 , a deflectable member  504 , and multiple spring attachment members  506 . The top  502  connects to or supports the lower surface of a pixel of the load support layer. The top  502  may define an opening  508  to facilitate the connection or interaction with a portion of a pixel.  
         [0085]     The deflectable member  504  shown in  FIG. 5  includes four angled sides  510 . The angled sides  510  connect to the top  502  of the spring member  124  and angle downward from the top  502  toward bottoms  512  of the angled sides  510 . The deflectable member  504  may define gaps  514  between the adjacent angled sides  510 . In  FIG. 5 , each gap  514  begins at the top  502  of the spring member  124  and widens along the length of the angled sides  510 . The deflectable member  504  may also define deflection slits  516  along the angled sides  510 . The deflection slits  516  may begin at some point between the top  502  of the spring member  124  and the bottoms  512  of the angled sides  510 , where the width of each deflection slit  516  gradually widens downward toward the bottom  512  of the angled sides  510 . The gaps  514  defined between adjacent angled sides  510 , as well as the deflection slits  516  defined along the angled sides  510 , help facilitate deflection of the spring  500  under a load.  
         [0086]     The four sided tower spring  500  may be tuned with varying deflection characteristics depending on where they are positioned within the micro compliance layer. Varying one or more of the design characteristics of the spring  500  may tune the spring element&#39;s deflection characteristics, such as spring rate.  
         [0087]     The following are examples of design variations that may be used to tune the four sided tower spring  500  to exhibit certain deflection characteristics. The slope, length, thickness, material and/or width of the angled sides  510  may vary. The angled sides  510  may not define a deflection slit  516 , or alternatively, may define the deflection slit  516  beginning closer or farther from the top  502  of the spring  500 . Similarly, the deflectable member  504  may not define gaps  514  between adjacent angled sides  510 , or alternatively, may define the gaps  514  beginning farther from the top  502  of the four sided tower spring  500 . Other variations in design characteristics of the spring element  124  may also affect the spring&#39;s  500  responsiveness to a load.  
         [0088]     At the bottoms  512  of the angled sides  510  the deflectable member  504  bends upwards and connects to the spring attachment members  506  for connection to the macro compliance layer. The spring attachment members  506  include a planar surface  512  in  FIG. 5 , but may alternatively include a non-planar, contoured, or other surface geometry. As described above, this connection may be an injection molding, a snap fit connection, or other connection method.  
         [0089]      FIG. 6  shows the four sided tower spring  500  deflecting under a load. When a load is applied to the load support layer, the lower surface of each pixel presses downward onto the top  502  of the corresponding four sided tower spring  500 . The deflectable member  504  bends to accommodate the load as the top  502  of the spring  500  is pressed downward. As described above, the gaps  514  and deflection slits  516  facilitate deflection under a load. For example, as the four sided tower spring  500  deflects under a load, the gaps  514  widen in response. Different initial gap  514  dimensions may be selected, among other deflection characteristics, to determine how far the four sided tower spring  500  deflects, as well as how much resistance to deflection the spring&#39;s  500  own structure may provide.  
         [0090]      FIG. 7  shows a plot  700  of the approximate spring rate of the four sided tower spring  500 . The plot  700  shows a non-linear decreasing spring rate  702  determined from a finite element analysis. According to the plot  700 , the force required to deflect the four sided tower spring  500  initially increases substantially linearly with respect to displacement, but substantially levels off when a designed amount of displacement has been achieved.  
         [0091]      FIG. 8  shows a top view of the macro and micro compliance layers of a suspended pixelated seating structure  800 .  FIG. 8  shows multiple tensile expansion members  802  defined along multiple primary support rails  804 . The multiple tensile expansion members  802  may be defined along the entire length, or a substantial portion, of the multiple primary support rails  804 , as shown in  FIG. 8 . Alternatively, the multiple tensile expansion members  802  may be defined along discrete segments of the multiple primary support rails  804 , such as in  FIG. 15 . The macro compliance layer includes the multiple primary support rails  804 , a support structure frame attachment  806 , and multiple secondary support rails  808  extending between and contacting adjacent multiple primary support rails  804 .  
         [0092]     The support structure frame attachment  806  includes a frame attachment rail  810  and frame connectors  812  defined along the frame attachment rail  810 . The frame connectors  812  shown in  FIG. 8  are openings  812  defined along the frame attachment rail  810 , but may alternatively be cantilevered elements or other elements for connecting the suspended pixelated seating structure  800  to the support structure frame. The support structure frame attachment  806  also includes multiple support rail connectors  814  for connecting the support structure frame attachment  806  to the multiple primary support rails  804 . This connection may be an integral molding, snap fit connection, or other connection method.  
         [0093]     As discussed above, where the macro compliance layer includes multiple tensile expansion members  802  defined along the multiple primary support rails  804 , the macro compliance layer may be injection molded from the more flexible materials, such as TPE&#39;s, TPU&#39;s, PP&#39;s, or other materials described as being used to form the support structure frame attachment shown in  FIG. 1 .  
         [0094]     The multiple tensile expansion members  802  may be defined along the entire length of the multiple primary support rails  804 , or along segmented portions of the multiple primary support rails  804 . Alternatively, the multiple tensile expansion members  802  may be defined along the multiple secondary support rails  808  instead of, or in addition to, being defined along the multiple primary support rails  804 .  
         [0095]     The multiple spring elements shown in  FIG. 8  are the four sided tower springs  500  described above. The spring attachment members  506  may include multiple spring connectors  816 . In  FIG. 8 , the multiple spring connectors  816  are openings defined within the spring attachment members  506 . The openings  816  may correspond to multiple support rail connectors  818  defined along the multiple primary and/or secondary support rails  804 ,  808 . The multiple spring connectors  816  and multiple support rails connectors  818  may be openings, protrusions, or other elements for connecting the four sided tower springs  500  to the multiple primary and/or secondary support rails  804 ,  808 . The multiple spring connectors  816  and multiple support rails connectors  818  may facilitate this connection through an integral molding, snap fit connection, or other connection method.  
         [0096]      FIG. 9  shows a coil spring  900 . The micro compliance layer may include one or more coil springs  900  as the multiple spring elements. The coil spring  900  includes a top  902 , deflectable member  904 , and spring attachment members  906 . The top may define an opening  908  for connection to a load support layer. The deflectable member  904  includes spiraled arms  904  which spiral from the top  902  of the spring element down to the spring attachment members  906 . Other sizes, shapes, and geometries of deflectable member may be additionally or alternatively implemented.  FIG. 9  shows elliptically shaped coil springs. The coil springs  900  may alternatively include other geometries, such as a circular geometry.  
         [0097]     Under a load, the top  902  of the coil spring  900  is pressed down and the coil spring  900  deflects or compresses in response. The coil spring  900  may exhibit an approximately linear or non-linear spring rate. As described above with reference to the four sided tower spring  500 , the deflection characteristics of the coil spring  900  may be tuned for various applications. For example, variation in pitch, thickness, length, degree of curvature, material, or other spiraled arm design characteristics may be selected to tune the deflection characteristics of the coil spring  900  for any desired stiffness or responsiveness.  FIG. 9  shows the coil spring  900  having different major and minor diameters, with the diameter of the coil spring gradually decreasing from the bottom (major diameter) towards the top (minor diameter). The coil spring  900  may alternatively include a substantially uniform diameter throughout the height of the coil spring  900  or may include other alternative variations in diameter.  
         [0098]      FIG. 10  shows a portion of a suspended pixelated seating structure  1000  in which the multiple spring elements are coil springs  900 . The pixelated seating structure includes a macro compliance layer  1002 , a micro compliance layer  1004 , and a load support layer. The macro compliance layer  1002  includes multiple primary support rails  1006  and a support structure frame attachment  1008 . The macro compliance layer  1002  also includes multiple tensile expansion members  1010  and multiple nodes  1012  defined along multiple primary support rails  1006 . The nodes  1012  include posts  1014  for connection to the micro compliance layer  1004 . The macro compliance layer  1002  further includes multiple expansion control strands  1016  extending between adjacent primary support rails  1006 . The support structure frame attachment  1008  includes a frame attachment rail  1018  and multiple frame connectors  1020 . The multiple frame connectors  1020  in  FIG. 10  include multiple openings  1020  defined along the frame attachment rail  1018  for connection to a support structure frame.  
         [0099]     Each of the multiple expansion control strands  1016  include a U-shaped bend  1022  to allow slack for the controlled separation of adjacent primary support rails  1006  when under a load. The multiple expansion control strands  1016  may alternatively be linear. In other examples, the macro compliance layer  1002  may omit the multiple expansion control strands  1016 . The bend  1022  may be varied to provide different amounts of slack, such as by changing the number of bends  1022 , the degree of curve in the bends  1022 , the length of the bends  1022 , the material from which the bends  1022  are made, or other design characteristics.  
         [0100]      FIG. 10  shows the multiple coil springs  900  positioned above the multiple expansion control strands  1016 . Alternatively or additionally, one or more coil springs  900  may be positioned above the space  1024  defined between adjacent primary support rails  1006  and adjacent expansion control strands  1016 .  
         [0101]     The micro compliance layer  1004  includes the multiple coil springs  900  and multiple deflection control runners  1026 . The multiple deflection control runners  1026  connect to and extend between spring attachment members  906  of adjacent coil springs  900 . The multiple deflection control runners  1026  may run substantially parallel to the multiple primary support rails  1006 . The multiple deflection control runners  1026  include multiple bends  1028  for controlled deflection of the suspended pixelated seating structure  1000 . The multiple deflection runners  1026  may alternatively be linear, or may be omitted from the micro compliance layer  1004 . The multiple deflection control runners  1026  may also be varied, such as by changing the number of multiple bends  1028 , the degree of curve in the multiple bends  1028 , the length of the bends  1028 , the material from which the bends  1028  are made, or other design characteristics.  
         [0102]      FIG. 10  shows multiple deflection control runners  1026  positioned over every other primary support rail  1006 . The deflection control runners  1026  may be positioned over all primary support rails  1006 , or over some smaller number of primary support rails  1006 . Additionally, the deflection control runners  1026  may run continuously along the length of the corresponding primary support rail  1006 , or may run along the length of the corresponding primary support rail  1006  in discrete segments.  
         [0103]     As the suspended pixelated seating structure  1000  deflects down under a load, the multiple tensile expansion members  1010  allow expansion along the length of the multiple primary support rails  1006 . The multiple deflection control runners  1026  straighten as the multiple primary support rails  1006  deflect downward and become taut when the multiple primary support rails  1006  have deflected by a certain amount. The amount of deflection exhibited by the multiple primary support rails  1006  before the multiple deflection control runners  1026  tauten may be tuned by adjusting various characteristics of the deflection control runners  1026 , including thickness, number of bends, degree of curve in the bends  1028 , or other characteristics.  
         [0104]     Each coil spring  900  defines an opening  1030  in each of the multiple spring attachment members  906  for receiving the multiple posts  1014  protruding up from the multiple nodes  1012 . The spring attachment members  906  may connect to the multiple posts  1014  with a snap fit connection, may be integrally molded, or may connect through a variety of other connection methods. Alternatively, the coil springs  900  may include multiple posts protruding down from the spring attachment members  906  for connection to multiple openings defined in the multiple nodes  1012 .  
         [0105]      FIG. 11  shows a broader view of the suspended pixelated seating structure  1000  shown in  FIG. 10 .  FIG. 10  shows a second support structure frame attachment  1100  connected to the multiple primary support rails  1006 . A load support layer connects on the micro compliance layer  1004 .  
         [0106]      FIG. 12  shows a squiggle spring  1200  connected between adjacent primary support rails  1202  and adjacent secondary support rails  1204 . The squiggle spring  1200  may be used as a spring element in any of the seating structures. The squiggle spring  1200  includes a top  1206  and a deflectable member  1208 . The squiggle spring  1200  includes an opening  1210  defined within the top  1206  for connection to a load support layer. The deflectable member  1208  includes a shaft  1212  extending downward from the top  1206  and curved strands  1214  connected to and extending from the shaft  1212 . The shaft  1212  includes a base  1216 . The curved strands  1214  may connect to and extend between the base  1216  of the shaft  1212  and, extending from the base  1216  and connecting to the primary support rails  1202  and/or secondary support rails  1204 . In  FIG. 12 , the curved strands  1214  are integrally molded between the base  1216  and the support rails  1202  and  1204 . The curved strands  1214  shown in  FIG. 12  include an approximate 7 mm×3 mm thickness.  
         [0107]     The curved strands  1214  include a multiple bends  1218 . As the top  1206  of the squiggle spring  1200  is pressed down under a load, the curved strands  1214  initially provide minimal resistance as the spring  1200  deflects downward. The spring  1200  continues to deflect downward until the curved strands  1214  become taut. When the curved strands  1214  tauten, the force necessary to continue deflecting the spring  1200  substantially increases. As such, the squiggle spring  1200  may provide a non-linear increasing spring rate. The spring rate may be tuned for various application, such as by varying the number of bends  1218  in the curved strands  1214 , the degree of curve in the bends  1218 , the number of curved strands  1214  connected between the shaft  1212  and the multiple primary and/or secondary support rails  1202 ,  1204 , the thickness of the curved strands  1214 , or by varying other design characteristics.  
         [0108]     The height of the shaft  1212  may vary as well. For example, where the spring deflection level described above is defined as 25 mm, the shaft  1212  may extend up to 25 mm above the macro compliance layer. In this example, the top  1206  of the squiggle spring  1200  may connect to the lower surface of a corresponding pixel, rather than connecting to a stem extending from the lower surface of the pixel. Where the suspended pixelated seating structure includes a load support layer including multiple stems, the height of the shaft  1212  may be designed such that when connected, the combined height of the shaft  1212  and corresponding stem equals the spring deflection level.  
         [0109]      FIG. 12  shows the shaft  1212  as a cylindrical shaft  1212 . The geometry of the shaft  1212 , however, may vary. For example, the shaft  1212  may extend from the top  1206  with no slope, or with some amount of slope, giving the shaft  1212  a conical shape. The shaft  1212  may include other geometries or configurations as well.  
         [0110]      FIG. 12  shows multiple expansion control strands  1220  extending from the multiple primary support rails  1202  and multiple recessed segments  1222  defined along the multiple primary support rails  1202 . Each multiple expansion control strand  1220  may define an opening  1224  for connection to the corresponding recessed segment  1222  of an adjacent primary support rail  1202 . Each recessed segment  1222  may also define an opening  1226  to facilitate this connection. The multiple expansion control strands  1220  may be non-linear.  
         [0111]      FIG. 13  shows the top view of a portion of a suspended pixelated seating structure  1300  where the multiple spring elements are squiggle springs  1200 .  FIG. 14  shows an offset top view of the portion of the suspended pixelated seating structure  1300  shown in  FIG. 13 . The suspended pixelated seating structure using squiggle springs  1200  includes multiple primary support rails  1202 , multiple secondary support rails  1204 , and support structure frame attachments  1302  connected at opposite ends of the primary support rails  1202 . The suspended pixelated seating structure  1300  also includes multiple tensile expansion members  1304  defined along the multiple primary support rails  1202 . The squiggle springs  1200  shown in these Figures are integrally molded between adjacent primary and secondary support rails  1202 ,  1204 .  
         [0112]      FIG. 15  shows a portion of a suspended pixelated seating structure  1500  where the micro compliance layer  1502  includes two sided tower springs  1504 . The two sided tower springs  1504  is another alternative for the spring element. The suspended pixelated seating structure also includes a macro compliance layer  1506  integrally connected to the micro compliance layer  1502 .  
         [0113]     The macro compliance layer  1506  includes multiple primary support rails  1508  and multiple expansion control strands  1510 .  FIG. 15  shows the primary support rails  1508  in cross-section, shown by the planar sides  1512 . The structure  1500  is a representative portion of a larger suspended pixelated seating structure. The suspended pixelated seating structure  1500  also includes multiple tensile expansion members  1514  and multiple unaligned segments  1516  defined along the multiple primary support rails  1508 . The multiple unaligned segments  1516  may alternatively be partially aligned, such as what aligning may incidentally result from aligning other portions of the multiple primary support rails  1508 .  
         [0114]     The multiple expansion control strands  1510  shown in  FIG. 15  are linear, but may alternatively be non-linear. The multiple expansion control strands  1510  have an approximate thickness of 1.5 mm. This thickness may be varied according to a number of factors, including whether the multiple expansion control strands incorporate one or more non-linear segments.  
         [0115]     The two sided tower springs  1504  include a top  1518 , a deflectable member  1520  including two sides, and multiple spring attachment members  1522 . The two sided tower springs  1504  may define an opening  1524  within the top  1518  for connection to the load support layer. The sides of the deflectable member  1520  include bottoms  1526  connected to the spring attachment members  1522 . The sides of the deflectable member  1520  extend downwards from the top  1518  towards their respective bottoms  1526 . The bottoms  1526  of the deflectable member  1520  curve upward and connect to the spring attachment members  1522 . The spring attachment members  1522  are integrally molded to the unaligned segments  1516  on adjacent primary support rails  1508 . Alternatively, the spring attachment members  1522  may connect to the unaligned segments  1516  with a snap fit connection or other connection method.  
         [0116]      FIG. 16  shows a broader view of the portion of the suspended pixelated seating structure  1500  shown in  FIG. 15 .  FIG. 16  shows the suspended pixelated seating structure  1500  further including support structure frame attachments  1600  positioned at opposite ends of the suspended pixelated seating structure  1500 .  FIGS. 17 and 18  respectively show a top view and a side view of the suspended pixelated seating structure  1500  shown in  FIG. 16 .  
         [0117]      FIG. 19  shows a portion of a load support layer  1900  that may be used in a suspended pixelated seating structure. The load support layer  1900  including multiple rectangular pixels  1902  interconnected at their corners with pixel connectors  1904 . Each of the multiple pixels  1902  includes an upper surface  1906  and a lower surface. The multiple pixels  1902  are shown as rectangular, but may take other shapes, such as hexagons, octagons, triangles, or other shapes. The lower surface includes a stem  1908  extending from the lower surface for connection to the micro compliance layer. Each multiple pixel connector  1904  interconnects four pixels  1902  at their respective corners. As described below and shown in  FIGS. 21-22 , the multiple pixel connectors  1904  may alternatively interconnect the multiple pixels  1902  at their respective sides. As yet another alternative, the multiple pixels  1902  may be arranged in a brick pattern. In this alternative, the multiple pixel connectors  1904  may interconnect three pixels at the corner of two pixels and the side of a third pixel.  
         [0118]      FIG. 19  shows the multiple pixel connectors  1904  as planar surfaces, recessed below the upper surface  1906  of the multiple pixels  1902 . Alternatively, the multiple pixel connectors  1904  may be non-planar and/or contoured. The multiple pixels  1902  may also be positioned on even plane with the multiple pixels  1902 .  
         [0119]     The multiple pixels  1902  may define multiple openings  1910  within each pixel. The openings  1910  begin near the center of the pixel  1902  and gradually widen toward the edge of each pixel. The openings  1910  may add flexibility to load support layer  1900  in adapting to a load.  FIG. 19  shows a load support layer  1900  including eight triangular openings  1910  defined within each pixel. The load support layer  1900 , however, may define any number of openings  1910  within each pixel  1902 , including zero or more openings  1910 . Additionally, each pixel  1902  within the load support layer  1900  may define a different number of openings  1910  or different sized openings  1910 , depending, for example, on the pixel&#39;s  1902  respective position within the load support layer  1900 .  
         [0120]      FIG. 19  shows circular connectors  1912 , each defining an opening at its center, positioned at the outside corners of the outside pixels  1902 . The circular connectors  1912  may provide anchor points for connecting the load support layer  1900  to the support structure. The circular connectors  1912  may be replaced by the multiple pixel connectors  1904  in other implementations.  
         [0121]      FIG. 20  shows a side view of the load support layer  1900  shown in  FIG. 19 .  FIG. 20  shows the upper and lower surfaces  1906  and  2000  of the multiple pixels  1902 . As described above, the lower surface  2000  of each pixel  1902  may define or include a stem  1908  extending down toward the micro compliance layer. The stem  1908  includes a shaft  2002  and flaps  2004  extending outward from the shaft  2002  along the length of the shaft  2002 . The flaps  2004  may include a cutoff bottom edge  2006  for abutment with the top of a corresponding spring element. For example, the portion  2008  of the shaft  2002  that extends beyond the cutoff bottom edge  2006  may insert into an opening defined within the top of the spring element until the cutoff bottom edge  2006  is flush with the top of the spring element. In this manner, when a load is applied to the load support layer  1900 , the cutoff bottom edge  2006  presses down on the top of the spring element. The length of the shaft  2002 , or whether a stem  1908  is included at all, may depend on the spring deflection level, as described above.  
         [0122]      FIG. 21  shows a load support layer  2100  including multiple rectangular pixels  2102  interconnected at their sides via pixel connectors  2104 . The multiple pixel connectors  2104  include U-shaped bends  2106  to provide slack for each pixel&#39;s  2102  independent movement when a load is applied. Other shapes, such as an S-shape, or other undulating shape may be implemented for the pixel connectors  2104 . The multiple pixel connectors  2104  may help reduce or prevent contact between adjacent pixels  2102  under deflection. The load support layer  2100  may alternatively omit the multiple pixel connectors  2104  to increase the independence of the multiple pixels  2102 . While  FIGS. 19 and 21  show load support layers  1900  and  2100  including rectangular pixels  1902  and  2102 , a load support layer may alternatively include circular, triangular, or other shaped pixels. The multiple pixels  2102  may also include alternative arrangements, including a brick pattern, such as the brick pattern arrangement described above.  
         [0123]      FIG. 22  shows a side view of the load support layer  2100  shown in  FIG. 21 .  FIG. 22  shows stems  2200  similar to the stems  1908  described above with reference to  FIG. 20 . Other stem types may be used as well. For example, the end of the stem  2200  may define an opening for receiving a stem extending upwards from the top of the spring element. As described above, a lower surface  2202  of the pixel may omit a stem  2200 , but rather connect to the top of the spring element.  
         [0124]      FIG. 23  shows a load support layer  2300  including multiple contoured pixels  2302 . The load support layer  2300  also includes multiple bridged connectors  2304  to facilitate the connections between adjacent pixels  2302 . In the example shown in  FIG. 23 , the bridged connectors  2304  are positioned at the corners of the pixels  2302 , but may alternatively be located at the sides of the pixels  2302 . The bridged connectors  2304  are described in more detail below and a close up of one bridge connector  2304  is shown in  FIG. 26 .  
         [0125]     The contoured pixels  2302  may provide enhanced flexibility, aeration, and/or aesthetics to the load support layer  2300  and are described in more detail below and shown in  FIG. 25 . The contoured pixels  2302  may include stems, such as the stems  1908  and  2200  described above, for connecting to a micro compliance layer.  
         [0126]      FIG. 24  shows a side view of the load support layer  2300  shown in  FIG. 23 .  FIG. 24  shows the multiple contoured pixels  2302  including stems  2400  extending downward for connecting to a micro compliance layer.  
         [0127]      FIG. 25  shows a close up of one of the contoured pixels  2302  shown in  FIG. 23 . The contoured pixel  2302  includes a pair of convex shaped sides  2500  and a pair of concave shaped sides  2502 . The contoured pixels  2302  are positioned such that every other pixel  2302  is rotated ninety degrees. In this manner the convex shaped sides  2500  of one pixel  2302  are adjacent to the concave shaped sides  2502  of an adjacent pixel  2302 , and visa versa.  
         [0128]     The contoured pixel  2302  may define multiple openings  2504  within the contoured pixel  2302  with a strip  2506  running between the openings  2504 . The strip  2506  running between the openings  2504  provides added flexibility to the pixel. The strip  2506  may be a non-linear strip  2506  (e.g., an undulating, S-shaped, U-shaped, or other shape strip). In implementations in which the contoured pixel  2302  includes the stem  2400  for connecting to a micro compliance layer, the stem  2400  may connect to the center of the strip  2506  and extend downward toward the top of the corresponding spring element. The contoured pixel  2302  includes a hinge  2508  running perpendicular to the strip  2506  for enhanced compliance when a load is applied. The hinge  2508  may be defined by a cut-out portion of the lower surface of the contoured pixel  2302  to enhance the flexibility of the contoured pixel  2302 .  
         [0129]      FIG. 26  shows four pixels  2600 - 2606  connected via the bridged connector  2304  shown in  FIG. 23 . The bridged connector  2304  includes a left U-shaped connector  2608 , a right U-shaped connector  2610 , and a bridge strip  2612 . The left and right U-shaped connectors  2608  and  2610  connect between the upper left and lower left pixels  2600  and  2602  and the upper right and lower right pixels  2604  and  2606  respectively. The left and right U-shaped connectors  2608  and  2610  bend downward, forming a left and a right U-shaped bend  2614  and  2616  respectively. The bridge strip  2612  includes cantilevered ends  2618 . The cantilevered ends  2618  connect above the left and right U-shaped bends  2614  and  2616 , forming a bridge between the two U-shaped bends  2614  and  2616 .  FIG. 26  shows a substantially linear bridge strip  2612 . The bridge strip  2612  may alternatively be non-linear.  
         [0130]     The bridged connectors  2304  provide an increased degree of independence as between adjacent pixels  2600 - 2606 , as well as enhanced flexibility to the load support layer  2300 . For example, the bridged connectors  2304  not only allow for flexible downward deflection, but also allow for individual pixels  2302  to independently move laterally in response to a load.  
         [0131]      FIG. 27  shows a side view of a suspended pixelated seating structure  2700  including multiple bolstering support members  2702 . The multiple bolstering support members  2702  may provide increase responsiveness to a load at the outer portions of the suspended pixelated seating structure  2700 , such as at the portions of the suspended pixelated seating structure  2700  that connect to a support structure frame  2718 . When a load is applied, the multiple bolstering support members  2702  may deflect downward, allowing for increased response to a load at the outer portions of the suspended pixelated seating structure  2700 . In this manner, the bolstering support members  2702  may allow for increased comfort and support provided by the suspended pixelated seating structure  2700 .  
         [0132]     The suspended pixelated seating structure includes a macro compliance layer  2704 , a micro compliance layer  2706 , and a load support layer  2708 . The macro compliance layer  2704  includes multiple primary support rails  2710 , with multiple nodes  2712  and multiple tensile expansion members  2714  defined along the multiple primary support rails  2710 . The micro compliance layer includes multiple spring elements  2716 .  FIG. 27  shows the suspended pixelated seating structure  2700  including multiple coil springs as the multiple spring elements  2716 . The suspended pixelated seating structure  2700 , however, may use other spring types, such as the spring types described above.  
         [0133]     Each bolstering support member  2702  includes an angled pad  2720 . Each bolstering support member  2702  may also include multiple connectors  2722  for connecting the bolstering support member  2702  to the macro and micro compliance layers  2704  and  2706 . The connectors  2722  may include cantilevered elements, openings defined in the angled pad, or other elements for connecting the bolstering support members to the macro and micro compliance layers  2704  and  2706 . While  FIG. 27  shows only connectors  2722  for connecting the bolstering support member  2702  to the macro compliance layer  2704 , other examples of the bolstering support member  2702  may include connectors  2722  for connecting the bolstering support member  2702  to the micro compliance layer  2706 . Alternatively, the macro and micro compliance layers  2704  and  2706  may connect directly to the angled pad  2718 . These connections may be a snap fit connection, an integral molding, or other connection method.  
         [0134]     The bolstering support member is positioned between the outer portion of the macro compliance layer  2704  and the outer portion of the micro compliance layer  2706 . For example, in  FIG. 27 , the bolstering support member  2702  is connected above the outer nodes  2712  of the multiple primary support rails  2710  via multiple connectors  2722 , and connected below the spring elements  2716  positioned at the outer portion of the micro compliance layer  2706 . The bolstering support member  2702  is positioned such that the angled pad  2720  angles upwards and outwards (relative to the macro compliance layer  2704 ) from the outer nodes  2712  to which the bolstering support member  2702  is connected. The degree of slope exhibited by the angled pad  2720  may be tuned according to the desired comfort and support characteristics of the suspended pixelated seating structure  2700 .  
         [0135]     The multiple spring elements  2716  may be connected along all or a portion the entire length of the upper surface of the angled pad  2720 . The connection between the bolstering support member  2702  and the macro and micro compliance layers  2704  and  2706  may be an integral molding, a snap fit connection, or other connection method. In this manner, the angled pad  2720  may deflect downward when a load is applied, thus providing increased deflection at the outer portions of the suspended pixelated seating structure  2700 .  
         [0136]     While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. For example, the springs may be implemented as any resilient structure that recovers its original shape when released after being distorted, compressed, or deformed. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Technology Category: a