EP3253256B1

EP3253256B1 - Office chair seating arrangement with headrest assembly

Info

Publication number: EP3253256B1
Application number: EP16747342.0A
Authority: EP
Inventors: Gordon Jay Peterson; Robert J. Battey; Bruce M. Smith; John A. Colasanti; Frederic Biddle; Todd D. Krupiczewicz
Original assignee: Steelcase Inc
Current assignee: Steelcase Inc
Priority date: 2015-02-06
Filing date: 2016-02-05
Publication date: 2021-10-27
Anticipated expiration: 2036-02-05
Also published as: CN116784616A; CN107205557A; EP3253256A4; EP3253256A1; WO2016127066A1

Description

TECHNICAL FIELD

Various embodiments relate to an office chair seating arrangement, and in particular to an office chair assembly that includes a headrest assembly having a pair of separately pivotable pivot adjustment arrangements and a vertical adjustment arrangement. In the prior art, GB2478851 discloses a backrest support assembly 1 for supporting, in use, the backrest of a wheelchair, e.g. when the wheelchair is supported on a wheelchair tilting platform [see Fig. 4], and comprises a backrest support 8 adjustably mounted on a stem 10 for height adjustment and/or angular adjustment relative to the stem. The backrest support 8 may be mounted on the stem 10 by a friction locking means, preferably a self-locking friction sleeve to allow continuous height adjustment. The backrest support 8 for the wheelchair backrest may rotate about the axis of the stem, preferably an axis transverse to the stem. An adjustable headrest 22 may be pivotally fitted to the stem 10 of the assembly. The stem 10 of the support assembly may be pivotally coupled to a base, e.g. a back wall of a tilting platform used to tilt a wheelchair. Also disclosed in GB2478851 is a backrest support assembly for supporting a wheelchair backrest wherein a backrest support is mounted to a stem by a friction locking sleeve. A further assembly is disclosed in which the stem of the backrest support assembly is pivotally mounted to a base to allow it to be rotated about a horizontal axis. Further examples of the state of the art are shown in DE 100 48 781 A1 , US 2013/093232 A1 .

BRIEF SUMMARY OF THE INVENTION

The present invention is set out in claim 1 of the appended claims. Preferred features are set out in dependent claims 2 to 11 of the appended claims. In one example not forming part of the invention, a seating arrangement includes a seat assembly adapted to support a user, a back assembly operably coupled to the seat assembly and adapted to support a user, and a headrest assembly coupled to the back assembly. The headrest assembly includes a support arrangement pivotably coupled to the back assembly for pivoting movement about a first pivot axis, a headrest member pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, and a sliding arrangement coupling the headrest member to the support arrangement to allow sliding vertical adjustment of the headrest member with respect to the support arrangement along an arcuate path.
In another example not forming part of the invention, a headrest assembly is adapted to couple to a seating arrangement that includes a support arrangement configured to pivotably couple to a back assembly of a seating arrangement for pivoting movement about a first pivot axis, a headrest member pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, and a sliding arrangement coupling the headrest member to the support arrangement, and configured to allow sliding vertical adjustment of the headrest member with respect to the support arrangement along an arcuate path.
In yet another example not forming part of the invention, a seating arrangement includes a seat assembly adapted to support a user, a back assembly operably coupled to the seat assembly and adapted to support a user, and a headrest assembly coupled to the back assembly. The headrest assembly includes a support arrangement coupled to the back assembly, a headrest member having an arcuately-shaped track portion, and a sliding arrangement slidably coupling the track portion of the headrest member to the support arrangement such that sliding adjustment of the headrest member with respect to the support arrangement causes the headrest member to travel along an arcuate path with respect to the support arrangement.
In still yet another example not forming part of the invention, a headrest assembly is adapted to couple to a seat arrangement that includes a support arrangement configured to operably couple to a back assembly of a seating arrangement, a headrest member having an arcuately-shaped support portion, and a sliding arrangement slidably coupling the support portion of the headrest member to the support arrangement such that sliding adjustment of the headrest member with respect to the support portion causes the headrest member to travel along an arcuate path with respect to the support arrangement.
In another r example not forming part of the invention, a seating arrangement includes a seat assembly adapted to support a user, a back assembly operably coupled to the seat assembly and adapted to support a user, and a headrest assembly coupled to the back assembly. The headrest assembly includes a support arrangement pivotably coupled to the back assembly for pivoting movement about a first pivot axis, a headrest member configured to support a user and pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, wherein the headrest member may be pivoted about the second pivot axis separately from the support arrangement being pivoted about the first pivot axis, and a coupling arrangement operably coupling the headrest member to the support arrangement such that the headrest member may be pivoted about a pivot area spaced from the first pivot axis and second pivot axis.
In yet another example not forming part of the invention, a headrest assembly is adapted to couple to a seat arrangement that includes a support arrangement configured to pivotably couple to a back assembly of a seating arrangement for pivoting movement about a first pivot axis, a headrest member pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, wherein the headrest member may be pivoted about the second pivot axis separately from the support arrangement being pivoted about the first pivot axis, and a coupling arrangement configured to operably couple the headrest member to the support arrangement such that the headrest member may be pivoted about a pivot area spaced from the first pivot axis and the second pivot axis.
In still yet another example not forming part of the invention, a seating arrangement includes a seat assembly adapted to support a user, a back assembly operably coupled to the seat assembly and adapted to support a user, and a headrest assembly coupled to the back assembly. The headrest assembly includes a support arrangement pivotably coupled to the back assembly for pivoting movement about a first pivot axis, wherein the support arrangement is located substantially in front of the back assembly when the headrest assembly is in a first position and substantially in back of the back assembly when the headrest assembly is in a second position, a headrest member including a support surface adapted to support a user and pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, wherein the support surface is substantially forwardly facing when the headrest assembly is in the first position and is substantially rearwardly facing when the headrest assembly is in the second position, and wherein the headrest member includes an upper edge and a lower edge when in the first position, and a sliding arrangement coupling the headrest member to the support arrangement to allow sliding vertical adjustment of the headrest member with respect to the support arrangement, and wherein the upper edge of the headrest member is located proximate the support arrangement when the headrest assembly is in the first position, and the lower edge of the headrest member is located proximate the support arrangement when the headrest assembly is in the second position.
Another example not forming part of the invention includes a seating arrangement that includes a seat assembly adapted to support a user, a back assembly operably coupled to the seat assembly and adapted to support a user, and a headrest assembly. The headrest assembly includes a headrest member adapted to support a user, a support arrangement operably coupling the headrest assembly to the back assembly such that the headrest member may be vertically adjusted with respect to the back assembly, wherein at least one of the headrest member and the support arrangement includes a first plurality of detents and a second plurality of detents, wherein detents of the first plurality of detents are offset from detents of the second plurality of detents, and an engagement member that alternately engages the first plurality of detents and the second plurality of detents as the headrest is vertically adjusted.
Yet another example not forming part of the invention includes a headrest assembly arrangement adapted to couple to a seating arrangement that includes a headrest member adapted to support a user, a support arrangement configured to operably couple the headrest member to a back assembly of a seating arrangement such that the headrest member may be vertically adjusted with respect to the back assembly, wherein at least one of the headrest member and the support arrangement includes a first plurality of detents and a second plurality of detents, wherein detents of the first plurality of detents are offset from detents of the second plurality of detents, and an engagement member that alternately engages the first plurality of detents and the second plurality of detents as the headrest is vertically adjusted.
Still yet another example not forming part of the invention includes a seating arrangement that includes a seat support structure that includes a seat support surface configured to support a seated user thereon, a back support structure that includes an upwardly extending portion adapted to move between an upright position and a reclined position, a control link coupled to the rearward portion of the seat support structure, and a second end coupled to the rearward portion of the back support structure, a back support surface that is generally forwardly facing and configured to support a back of a seated user, and having an upper portion coupled to the upwardly extending portion of the back support, and a lower portion, and a back link coupled to the lower portion of the back support surface and coupled to the seat support structure, wherein the back support surface is moved forward by the back link relative to the upwardly extending portion of the back support structure as the back support structure is moved from the upright position to the reclined position. The seat arrangement further includes a headrest assembly coupled to the back support structure that includes a support arrangement pivotably coupled to the back assembly for pivoting movement about a first pivot axis, a headrest member pivotably coupled to the support arrangement for pivoting movement about a second pivot axis that is spaced from the first pivot axis, and a sliding arrangement coupling the headrest member to the support arrangement, thereby allowing sliding vertical adjustment of the headrest member with respect to the back support structure.
These and other features and advantages of the various embodiments will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. Fig. 68-78 show embodiments according to the present invention as claimed. Fig. 1-67, 79-92 only show examples useful for understanding but not forming part of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a front perspective view of an example not forming part of the invention of a chair assembly;
Fig. 2 is a rear perspective view of the chair assembly;
Fig. 3 is a side elevational view of the chair assembly showing the chair assembly in a lowered position and in a raised position in dashed line, and a seat assembly in a retracted position and an extended position in dashed line;
Fig. 4 is a side elevational view of the chair assembly showing the chair assembly in an upright position and in a reclined position in dashed line;
Fig. 5A is an exploded view of the seat assembly;
Fig. 5B is an enlarged perspective view of the chair assembly with a portion of the seat assembly removed to illustrate a spring support assembly;
Fig. 6 is an exploded perspective view of the seat assembly;
Fig. 7 is a top perspective view of the seat assembly;
Fig. 8 is a bottom perspective view of the seat assembly;
Fig. 9 is an exploded bottom perspective view of the cover assembly and the seat assembly;
Fig. 10 is a cross-sectional view of the cover assembly;
Fig. 11 is an exploded perspective view of an alternative r example not forming part of the invention of the seat assembly;
Fig. 11A is an exploded perspective view of another alternative example not forming part of the invention of the seat assembly;
Fig. 12 is a top perspective view of the alternative example not forming part of the invention of the seat assembly;
Fig. 13 is a bottom perspective view of the alternative example not forming part of the invention of the seat assembly;
Fig. 14 is an exploded bottom perspective view of the alternative example not forming part of the invention of the seat assembly;
Fig. 15 is a top perspective view of a second alternative example not forming part of the invention of the seat assembly;
Fig. 16 is a cross-sectional view of the second alternative example not forming part of the invention of the seat assembly taken along the line XVI-XVI, Fig. 15;
Fig. 17 is a cross-sectional view of the second alternative example not forming part of the invention of the seat assembly taken along the line XVII-XVII, Fig. 15;
Fig. 18 is a front perspective view of a back assembly;
Fig. 19 is a side elevational view of the back assembly;
Fig. 20A is an exploded front perspective view of the back assembly;
Fig. 20B is an exploded rear perspective view of the back assembly;
Fig. 21 is an enlarged perspective view of an area XXI, Fig. 20A;
Fig. 22 is an enlarged perspective view of an area XXII, Fig. 2;
Fig. 23 is a cross-sectional view of an upper back pivot assembly taken along the line XXIII-XXIII, Fig. 18;
Fig. 24A is an exploded rear perspective view of the upper back pivot assembly;
Fig. 24B is an exploded front perspective view of the upper back pivot assembly;
Fig. 25 is an enlarged perspective view of the area XXV, Fig. 20B;
Fig. 26A is an enlarged perspective view of a comfort member and a lumbar assembly;
Fig. 26B is a rear perspective view of the comfort member and the lumbar assembly;
Fig. 27A is a front perspective view of a pawl member;
Fig. 27B is a rear perspective view of the pawl member;
Fig. 28 is a partial cross-sectional perspective view along the line XXVIII-XXVIII, Fig. 26B;
Fig. 29A is a perspective view of the back assembly, wherein a portion of the comfort member is cut away;
Fig. 29B is an enlarged perspective view of a portion of the back assembly;
Fig. 30 is a perspective view of an alternative example not forming part of the invention of the lumbar assembly;
Fig. 31 is a cross-sectional view of the back assembly and an upholstery assembly;
Fig. 32A-32D are stepped assembly views of the back assembly and the upholstery assembly;
Fig. 33 is an enlarged perspective view of the area XXXIII, Fig. 32A;
Figs. 34A-34H are a series of back elevational views of a boat cleat and the sequential steps of a drawstring secured thereto;
Figs. 35G and 35H are alternative sequential steps for securing the drawstring to the boat cleat;
Fig. 36 is an exploded view of an alternative example not forming part of the invention of the back assembly;
Fig. 37 is a cross-sectional side view of a top portion of the alternative example not forming part of the invention of the back assembly;
Fig. 38 is a cross-sectional side view of a side portion of the alternative example not forming part of the invention of the back assembly;
Fig. 39 is a front elevational view of a stay member;
Fig. 40 is a front elevational view of the stay member in an inside-out orientation;
Fig. 41 is a partial front elevational view of the stay member sewn to a cover member;
Fig. 42 is a perspective view of a control input assembly supporting a seat support plate thereon;
Fig. 43 is a perspective view of the control input assembly with certain elements removed to show the interior thereof;
Fig. 44 is an exploded view of the control input assembly;
Fig. 45 is a side elevational view of the control input assembly;
Fig. 46A is a front perspective view of a back support structure;
Fig. 46B is an exploded perspective view of the back support structure;
Fig. 47 is a side elevational view of the chair assembly illustrating multiple pivot points thereof;
Fig. 48 is a side perspective view of the control assembly showing multiple pivot points associated therewith;
Fig. 49 is a cross-sectional view of the chair showing the back in an upright position with the lumbar adjustment set at a neutral setting;
Fig. 50 is a cross-sectional view of the chair showing the back in an upright position with the lumbar portion adjusted to a flat configuration;
Fig. 51 is a cross-sectional view of the chair showing the back reclined with the lumbar adjusted to a neutral position;
Fig. 52 is a cross-sectional view of the chair in a reclined position with the lumbar adjusted to a flat configuration;
Fig. 52A is a cross-sectional view of the chair showing the back reclined with the lumbar portion of the shell set at a maximum curvature;
Fig. 53 is an exploded view of a moment arm shift assembly;
Fig. 54 is a cross-sectional perspective of the moment arm shift assembly taken along the line LIV-LIV, Fig. 43;
Fig. 55 is a top plan view of a plurality of control linkages;
Fig. 56 is an exploded view of a control link assembly;
Fig. 57A is a side perspective view of the control assembly with the moment arm shift in a low tension position and the chair assembly in an upright position;
Fig. 57B is a side perspective view of the control assembly with the moment arm shift in a low tension position and the chair assembly in a reclined position;
Fig. 58A is a side perspective view of the control assembly with the moment arm shift in a high tension position and the chair assembly in an upright position;
Fig. 58B is a side perspective view of the control assembly with the moment arm shift in a high tension position and the chair assembly in a reclined position;
Fig. 59 is a chart of torque vs. amount of recline for low and high tension settings;
Fig. 60 is a perspective view of a direct drive assembly with the seat support plate exploded therefrom;
Fig. 61 is an exploded perspective view of the direct drive assembly;
Fig. 62 is a perspective view of a vertical height control assembly;
Fig. 63 is a perspective view of the vertical height control assembly;
Fig. 64 is a side elevational view of the vertical height control assembly;
Fig. 65 is a cross-sectional perspective view of a first input control assembly taken along the line LXV-LXV, Fig. 42;
Fig. 66A is an exploded perspective view of a control input assembly;
Fig. 66B is an enlarged perspective view of a clutch member of a first control input assembly;
Fig. 66C is an exploded perspective view of the control input assembly;
Fig. 67 is a cross-sectional side elevational view of a variable back control assembly taken along the line LXVII-LXVII, Fig. 42;
Fig. 68 is a perspective view of an embodiment according to the invention of the chair assembly that includes a headrest assembly;
Fig. 69 is a rear perspective view of the headrest assembly;
Fig. 70A is an exploded rear perspective view of the headrest assembly;
Fig. 70B is an exploded rear perspective view of an alternative embodiment of the headrest assembly;
Fig. 71 is an exploded view of components of an alternative embodiment of the back shell;
Fig. 72 is a cross-sectional view of the headrest assembly, taken along the line LXXII-LXX11, Fig. 69;
Fig. 73 is a rear perspective view of a fabric member coupled with a subframe of the headrest assembly;
Fig. 74 is a cross-sectional view of the headrest assembly;
Fig. 75 is an enlarged view of the headrest assembly;
Fig. 76 is a rear perspective view of the headrest assembly with a cover removed;
Fig. 77 is a rear perspective view of the headrest assembly with the cover member and a guide member removed;
Figs. 78A-78K are side elevational views of the headrest assembly shown in various configurations and orientations;
Fig. 79 is a perspective view of another example not forming part of the invention of a chair assembly;
Fig. 80 is a front elevational view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 81 is a first side elevational view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 82 is a second side elevational view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 83 is a rear side elevational view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 84 is a top plan view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 85 is a bottom plan view of the example not forming part of the invention of the chair assembly of Figure 79;
Fig. 86 is a perspective view of another example not forming part of the invention of a chair assembly;
Fig. 87 is a front elevational view of the example not forming part of the invention of the chair assembly of Figure 86;
Fig. 88 is a first side elevational view of the example not forming part of the invention of the chair assembly of Figure 86;
Fig. 89 is a second side elevational view of the example not forming part of the invention of the chair assembly of Figure 86;
Fig. 90 is a rear side elevational view of the example not forming part of the invention of the chair assembly of Figure 86;
Fig. 91 is a top plan view of the example not forming part of the invention of the chair assembly of Figure 86; and
Fig. 92 is a bottom plan view of the example not forming part of the invention of the chair assembly of Figure 86.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to an example as oriented in Fig. 1. However, it is to be understood that various embodiments may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the 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. 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 may be 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 16a (Fig. 6) generally designates the seat assembly. Since the seat assembly 16a is similar to the previously described seat assembly 16, similar parts appearing in Figs. 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 16a includes a relatively rigid seat support plate 32a having a forward edge 34a, a rearward edge 36a, and a pair of C-shaped guide rails 38a defining the side edges of the seat support plate 32a and extending between the forward edge 34a and the rearward edge 36a. The seat assembly 16a further includes a flexibly resilient outer seat shell 40a (Figs. 6 and 7) having a pair of upwardly turned side portions 42a each terminating in a side edge 43a, a forward edge 45a, and an upwardly turned rear portion 44a that terminates in a rear edge 47a and includes a flap portion 49a, wherein the side portions 42a and rear portion 44a cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40a 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 40a is secured and sandwiched between the seat support plate 32a and a plastic, flexibly resilient seat pan 46a which is secured to the seat support plate 32a by a plurality of mechanical fasteners. The seat pan 46a includes a forward edge 48a, a rearward edge 50a, side edges 52a extending between the forward edge 48a and the rearward edge 50a, a top surface 54a and a bottom surface 56a that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan 46a includes a plurality of longitudinally extending slots 58a extending forwardly from the rearward edge 50a. The slots 58a cooperate to define a plurality of fingers 60a therebetween, each finger 60a being individually flexibly resilient. The seat pan 46a further includes a plurality of laterally oriented, elongated apertures 62a located proximate the forward edge 48a. The apertures 62a cooperate to increase the overall flexibility of the seat pan 46a in the area thereof, and specifically allow a forward portion 64a of the seat pan 46a to flex in a vertical direction 66a with respect to a rearward portion 68a of the seat pan 46a, as discussed further below. The seat assembly 16a further includes a foam cushion member 70a having an upper surface 76a, and that rests upon the top surface 54a of the seat pan 46a and is cradled within the outer seat shell 40a. The seat assembly 16a further includes a fabric seat cover 72a having a forward edge 73a, a rearward edge 75a and a pair of side edges 77a extending therebetween. The seat assembly 16a is supported by a spring support assembly 78a (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 40a and the fabric seat cover 72a cooperate to form an upholstery cover assembly or cover 100a. Specifically, the side edges 43a of the seat shell 40a and the side edges 77a of the seat cover 72a, the forward edge 45a of the seat shell 40a and the forward edge 73a of the seat cover 72a, and the rear edge 47a of the seat shell 40a and the rear edge 75a of the seat cover 72a are respectively attached to one another to form the cover 100a and to define an interior space 102a therein.
The flap portion 49a of the seat shell 40a includes a pair of corner edges 104a each extending along a corner 106a of the seat shell 40a located between the rear portion 44a and respective side portions 42a, such that the flap portion 49a is movable between an open position I and a closed position J. In the illustrated example, each corner edge 104a of the flap portion 49a includes a plurality of tabs 108a spaced along the corner edge 104a and each including an aperture 110a extending therethrough. The tabs 108a of the corner edge 104a are interspaced with a plurality of tabs 112a spaced along a corner edge 114a of each side portion 42a. Each of the tabs 112a includes an aperture 116a that extends therethrough. The seat shell 40a also includes a plurality of integrally-molded coupling tabs 118a spaced about an inner edge 121a of the seat shell 40a and each having a Z-shaped, cross-section configuration.
In assembly, the upholstery cover assembly 100a (Fig. 9) is constructed from the seat shell 40a and seat cover 72a as described above. The seat pan 46a, the cushion member 70a and the spring support assembly 78a are then arranged with respect to one another assembled with the upholstery cover assembly 100a by positioning the flap 49a in the open position I, positioning the seat pan 46a, the cushion member 70a and spring support assembly 78a within the interior space 102a, and then moving the flap 49a to the closed position J. A pair of quick-connect fasteners 120a each include a plurality of snap couplers 122a spaced along the length of an L-shaped body portion 124a. In assembly, the snap couplers 122a are extended through the apertures 110a, 116a of the tabs 108a, 112a, and are snapably received within corresponding apertures 126a of the seat pan 46a, thereby securing the corner edges 104a, 114a to the seat pan 46a and the flap portion 49a in the closed position J.
Further in assembly, the coupling tabs 118a (Fig. 10) are positioned within corresponding apertures 130a of the seat pan 46a, such that the cover assembly 100a is temporarily secured to the seat pan 46a, thereby allowing further manipulation of the cover seat assembly 16a during assembly while maintaining connection and alignment of the cover assembly 100a with the seat pan 46a. As used herein, "temporarily securing" is defined as a securing not expected to maintain the securement of the cover assembly 100a to the seat pan 46a by itself during normal use of the chair assembly throughout the normal useful life of the chair assembly. The support plate 32a is then secured to an underside of the seat pan 46a by a plurality of screws 132a, thereby sandwiching the coupling tabs 118a between the support plate 32a and the seat pan 46a, and permanently securing the cover assembly 100a to the seat pan 46a. As used herein, "permanently securing" is defined as a securing expected to maintain the securement of the cover assembly to the seat pan 46a during normal use of the chair assembly throughout the normal useful life of the chair assembly.
The reference numeral 16b (Fig. 11) generally designates the seat assembly. Since the seat assembly 16b is similar to the previously described seat assemblies 16 and/or seat assembly 16a, 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 16b is similar in configuration and construction to the seat assembly 16 and the seat assembly 16a, with the most notable exception being an alternatively, configured and constructed outer seat shell 40b and upholstery cover 100b.
The seat assembly 16b (Fig. 11) includes a flexibly resilient outer seat shell 40b having a pair of upwardly turned side portions 42b each terminating in a side edge 43b, a forward edge 45b, and an upwardly turned rear portion 44b that terminates in a rear edge 47b, wherein the side portions 42b and rear portion 44b cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40b 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 40b is secured and sandwiched between the seat support plate 32b, a plastic, flexibly resilient seat pan 46b and a plastic, substantially rigid overlay 51b, each of which is secured to the seat support plate 32b by a plurality of mechanical fasteners. The overlay 51b has an upwardly arcuate shape and includes a rear wall 53b and a pair of forwardly-extending sidewalls 55b each including a forward-most edge 57b, and wherein the rear wall 53b and sidewalls 55b cooperate to form an uppermost edge 59b. The seat pan 46b includes a forward edge 48b, a rearward edge 50b, side edges 52b extending between the forward edge 48b and the rearward edge 50b, a top surface 54b and a bottom surface 56b that cooperate to form an upwardly disposed generally concave shape.
As best illustrated in Figs. 12 and 13, the flexible resilient seat shell 40b, the fabric seat cover 72b and the overlay 51b cooperate to form an upholstery cover assembly or cover 100b. In the illustrated example, the side edges 43b of the seat shell 40b and the side edges 77b of the seat cover 72b, the forward edge 45b of the seat shell 40b and the forward edge 73b of the seat cover 72b, and the rear edge 47b of the seat shell 40b and the rear edge 75b of the seat cover 72b are respectively attached to one another, such that the seat shell 40b and the fabric seat cover 72b cooperate with the overlay 51b to form the cover 100b and to define an interior space 102b therein. The seat shell 40b also includes a plurality of integrally-molded coupling tabs 118b spaced about an inner edge 121b of the seat shell 40b and each having a Z-shaped, cross-section configuration.
In assembly, the seat shell 40b (Fig. 14) and seat cover 72b of the upholstery cover 100b are coupled to one another as described above. As best illustrated in Figs. 15 and 16, the side portions 42b of the seat shell 40b are coupled to the fabric seat cover 72b so as to define a corner 79b therebetween. It is noted that use of both the fabric material of the fabric seat cover 72b and the TPE of the seat shell 40b 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 46b, the cushion member 70b and the spring support assembly 78b are then arranged with respect to one another and positioned within the interior space 102b of the cover 100b. The shell 40b is then secured to the seat pan 46b for displacement in a lateral direction by a plurality of integral hook-shaped couplers 123b spaced about the periphery of the shell 40b and which engage a downwardly-extending trim portion 125b extending about the side and rear periphery of the seat pan 46b. The shell 40b (Fig. 17) further includes a plurality of Z-shaped couplers 127b integral with the shell 40b and received within corresponding apertures 129b of the seat pan 46b, thereby temporarily securing the shell 40b to the seat pan 46b with respect to vertical displacement.
Further in assembly, the overlay 51b (Fig. 17) includes a plurality of integrally formed, L-shaped hooks 131b spaced along the sidewalls 55b and that slidably engage a corresponding plurality of angled couplers 133b integrally formed with the seat pan 46b. Specifically, the hooks 131b engage the couplers 133b as the overlay 51b is slid forwardly with respect to the seat pan 46b. The overlay 51b is then secured in place by a pair of screws 135b that extend through corresponding apertures 137b of the overlay 51b and are threadably received within corresponding bosses 139b of the seat pan 46b, thereby trapping the couplers 127b within the apertures 129b. The support plate 32b is then secured to an underside of the seat pan 46b by a plurality of screws 132b, thereby sandwiching a plurality of spaced coupling tabs 141b integral with the overlay 51b between the support plate 32b and the seat pan 46b, and permanently securing the cover assembly 100b to the seat pan 46b. It is noted that the terms "temporarily securing" and "permanently securing" are previously defined herein.
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 306 of the comfort member 298 and the side edge 222 of the back shell 216. Alternatively, the lumbar assembly 300c (Fig. 30) is provided wherein the body portion 326c and the support portion 328c are integrally formed, and the handles 346c are formed separately from the body portion 326c and are attached thereto. In the alternative example not forming part of the invention, each handle 346c includes a pair of blades 350c received within corresponding pockets 352c of the body portion 326c. Each blade 350c includes a pair of snap tabs 354c spaced along the length thereof and which snappingly engage an edge of one of a plurality of apertures 356c within the body portion 326c.
In operation, a user adjusts the relative vertical position of the lumbar assembly 300, 300c with respect to the back shell 216 by grasping one or both of the handle portions 346, 346c and sliding the handle assembly 346, 346c 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. 35I and 35J 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 18d (Fig. 36) generally designates the back assembly. Since back assembly 18d 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 18d includes a back frame assembly 200d, a back shell 216d, and an upholstery cover assembly 400d. In the illustrated example, the back shell 216d includes a substantially flexible outer peripheral portion 450d (Figs. 37 and 38) and a substantially less flexible rear portion 452d to which the peripheral portion 450d is attached. The rear portion 452d includes a plurality of laterally extending, vertically spaced slots 454d that cooperate to define slats 456d therebetween. The peripheral portion 450d and the rear portion 452d cooperate to form an outwardly facing opening 458d extending about a periphery of the back shell 216d. The rear portion 452d includes a plurality of ribs 460d spaced about the opening 458d and are utilized to secure the cover assembly 400d to the back shell 216d as described below.
The cover assembly 400d includes a fabric cover 462d and a stay-member 464d extending about a peripheral edge 466d of the fabric cover 462d. The fabric cover 462d includes a front surface 468d and a rear surface 470d 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 464d is ring-shaped and includes a plurality of widened portions 472d each having a rectangularly-shaped cross-sectional configuration interspaced with a plurality of narrowed corner portions 474d each having a circularly-shaped cross-sectional configuration. Each of the widened portions 472d include a plurality of apertures 476d spaced along the length thereof and adapted to engage with the ribs 460d of the back shell 216d, as described below. The stay member 464d is comprised of a relatively flexible plastic such that the stay member 464d may be turned inside-out, as illustrated in Fig. 40.
In assembly, the stay member 464d is secured to the rear surface 470d of the cover 462d such that the cover 462d is fixed for rotation with the widened portions 472d, and such that the cover 462d is not fixed for rotation with the narrowed corner portions 474d along a line tangential to a longitudinal axis of the narrowed corner portions 474d. In the present example, the stay member 464d (Fig. 41) is sewn about the peripheral edge 466d of the cover 462d by a stitch pattern that extends through the widened portions 472d and about the narrowed corner portions 474d. The cover assembly 400d of the cover 462d and the stay member 464d are aligned with the back shell 216d, and the peripheral edge 466d of the cover 462d is wrapped about the back shell 216d such that the stay member 464d is turned inside-out. The stay member 464d is then inserted into the opening or groove 458d, such that the tension of the fabric cover 462d being stretched about the back shell 216d causes the stay member 464d to remain positively engaged within the groove 458d. The ribs 460d of the back shell 216d engage the corresponding apertures 476d of the stay member 464d, thereby further securing the stay member 464d within the groove 458d. It is noted that the stitch pattern attaching the cover 462d to the stay member 464d allows the narrowed corner portions 474d of the stay member 464d to rotate freely with respect to the cover 462d, thereby reducing the occurrence of aesthetic anomalies near the corners of the cover 462d, 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.
The control assembly 14 further includes a back support structure 542 having a generally U-shaped plan view configuration and including a pair of forwardly extending arm portions 544 each including a pivot aperture 546 and pivotably coupled to the base structure 502 by a pivot shaft 548 such that the back support structure 542 pivots about the lower and forward pivot point 518. The back support structure 542 includes a rear portion 550 that cooperates with the arm portions 544 to define an interior space 552 which receives the base structure 502 therein. The back support structure 542 further includes a pair of pivot apertures 554 located along the length thereof and cooperating to define a pivot point 556. It is noted that in certain instances, at least a portion of the back frame assembly 200 may be included as part of the back support structure 542.
The control assembly 14 further includes a plurality of control links 558 each having a first end 560 pivotably coupled to the seat support structure 522 by a pair of pivot pins 562 for pivoting about the pivot point 540, and a second end 564 pivotably coupled to corresponding pivot apertures 554 of the back support structure 542 by a pair of pivot pins 566 for pivoting about the pivot point 556. In operation, the control links 558 control the motion, and specifically the recline rate of the seat support structure 522 with respect to the back support structure 542 as the chair assembly is moved to the recline position, as described below.
As best illustrated in Figs. 46A and 46B, the bottom frame portion 206 of the back frame assembly 200 is configured to connect to the back support structure 542 via a quick connect arrangement 568. Each arm portion 544 of the back support structure 542 includes a mounting aperture 570 located at a proximate end 572 thereof. In the illustrated example, the quick connect arrangement 568 comprises a configuration of the bottom frame portion 206 of the back frame assembly 200 that includes a pair of forwardly-extending coupler portions 574 that cooperate to define a channel 576 therebetween that receives the rear portion 550 and the proximate ends 572 of the arm portions 544 therein. Each coupler portion 574 includes a downwardly extending boss 578 that aligns with and is received within a corresponding aperture 570. Mechanical fasteners, such as screws 580 are then threaded into the bosses 578, thereby allowing a quick connection of the back frame assembly 200 to the control assembly 14.
As best illustrated in Fig. 47, the base structure 502, the seat support structure 522, the back support structure 542 and the control links 558 cooperate to form a four-bar linkage assembly that supports the seat assembly 16, the back assembly 18, and the arm assemblies 20 (Fig. 1). For ease of reference, the associated pivot assemblies associated with the four-bar linkage assembly of the control assembly 14 are referred to as follows: the upper and forward pivot point 516 between the base structure 502 and the base support structure 522 as the first pivot point 516; the lower and forward pivot point 518 between the base structure 502 and the back support structure 542 as the second pivot point 518; the pivot point 540 between the first end 560 of the control link 558 and the seat support structure 522 as the third pivot point 540; and, the pivot point 556 between the second end 564 of the control link 558 and the back support structure 542 as the fourth pivot point 556. Further, Figure 47 illustrates the component of the chair assembly 10 shown in a reclined position in dashed lines, wherein the reference numerals of the chair in the reclined position are designated with a " ' ".
In operation, the four-bar linkage assembly of the control assembly 14 cooperates to recline the seat assembly 16 from the upright position G to the reclined position H as the back assembly 18 is moved from the upright position E to the reclined position F, wherein the upper and lower representations of the positions E and F in Fig. 47 illustrates that the upper and lower portions of the back assembly 18 recline as a single piece. Specifically, the control link 558 is configured and coupled to the seat support structure 522 and the back support structure 542 to cause the seat support structure 522 to rotate about the first pivot point 516 as the back support structure 542 is pivoted about the second pivot point 518. Preferably, the seat support structure 522 is rotated about the first pivot point 516 at between about 1/3 and about 2/3 the rate of rotation of the back support structure 542 about the second pivot point 518, more preferably the seat support structure 522 rotates about the first pivot point 516 at about half the rate of rotation of the back support structure 542 about the second pivot point 518, and most preferable the seat assembly 16 reclines to an angle β of about 9° from the fully upright position G to the fully reclined position H, while the back assembly 18 reclines to an angle γ of about 18° from the fully upright position E to the fully reclined position F.
As best illustrated in Fig. 47, the first pivot point 516 is located above and forward of the second pivot point 518 when the chair assembly 10 is at the fully upright position, and when the chair assembly 10 is at the fully reclined position as the base structure 502 remains fixed with respect to the supporting floor surface 13 as the chair assembly 10 is reclined. The third pivot point 540 remains behind and below the relative vertical height of the first pivot point 516 throughout the reclining movement of the chair assembly 10. It is further noted that the distance between the first pivot point 516 and the second pivot point 518 is greater than the distance between the third pivot point 540 and the fourth pivot point 556 throughout the reclining movement of the chair assembly 10. As best illustrated in Fig. 48, a longitudinally extending center line axis 582 of the control link 558 forms an acute angle α with the seat support structure 522 when the chair assembly 10 is in the fully upright position and an acute angle α' when the chair assembly 10 is in the fully reclined position. It is noted that the center line axis 582 of the control link 558 does not rotate past an orthogonal alignment with the seat support structure 522 as the chair assembly 10 is moved between the fully upright and fully reclined positions thereof.
With further reference to Fig. 49, a back control link 584 includes a forward end 585 that is pivotably coupled or connected to the seat support structure 522 at a fifth pivot point 586. A rearward end 588 of the back control link 584 is connected to the lower portion 220 of the back shell 216 at a sixth pivot point 590. The sixth pivot point 590 is optional, and the back control link 584 and the back shell 216 may be rigidly fixed to one another. Also, the pivot point 590 may include a stop feature that limits rotation of the back control link 584 relative to the back shell 216 in a first and/or second rotational direction. For example, with reference to Fig. 49, the pivot point 590 may include a stop feature 592 that permits clockwise rotation of the lower portion 220 of the back shell 216 relative to the control link 584. This permits the lumbar to become flatter if a rearward/horizontal force tending to reduce dimension D₁ is applied to the lumbar portion of the back shell 216. However, the stop feature 592 may be configured to prevent rotation of the lower portion 220 of the back shell 216 in a counter clockwise direction (Fig. 49) relative to the control link 584. This causes the link control 584 and the lower portion 220 of the back shell 216 to rotate at the same angular rate as a user reclines in the chair by pushing against an upper portion of back assembly 18.
A cam link 594 is also pivotably coupled or connected to the seat support structure 522 for rotation about the pivot point or axis 586. The cam link 594 has a curved lower cam surface 596 that slidably engages an upwardly facing cam surface 598 formed in the back support structure 542. A pair of torsion springs 600 (see also Fig. 29A) rotatably bias the back control link 584 and the cam link 594 in a manner that tends to increase the angle ∅ (Fig. 49). The torsion springs 600 generate a force tending to rotate the control link 584 in a counter-clockwise direction, and simultaneously rotate the cam link 594 in a clockwise direction. Thus, the torsion springs 600 tend to increase the angle ∅ between the back control link 584 and the cam link 594. The stop feature 592 on the seat support structure 522 limits counter clockwise rotation of the back control link 584 to the position shown in Fig. 49. This force may also bias the control link 584 in a counter clockwise direction into the stop feature 592.
As discussed above, the back shell 216 is flexible, particularly in comparison to the rigid back frame structure 200. As also discussed above, the back frame structure 200 is rigidly connected to the back support structure 542, and therefore pivots with the back support structure 542. The forces generated by the torsion springs 600 push upwardly against the lower portion 220 of the back shell 216. As also discussed above, the slots 244 in the back shell structure 216 create additional flexibility at the lumbar support portion or region 242 of the back shell 216. The force generated by the torsion springs 600 also tend to cause the lumbar portion 242 of the back shell 2126 to bend forwardly such that the lumbar portion 242 has a higher curvature than the regions adjacent the torsional springs 600.
As discussed above, the position of the lumbar assembly 300 is vertically adjustable. Vertical adjustment of the lumbar assembly 300 also adjusts the way in which the back shell 216 flexes/curves during recline of the chair back 18. For example, when, the lumbar assembly 300 is adjusted to an intermediate or neutral position, the curvature of the lumbar portion 242 (Fig. 49) of the back shell 216 is also intermediate or neutral. If the vertical position of the lumbar assembly 300 is adjusted, the angle ∅ (Fig. 50) is reduced, and the curvature of the lumbar portion 242 is reduced. As shown in Fig. 50, this also causes angle ∅₁ to become greater, and the overall shape of the back shell 216 to become relatively flat.
With further reference to Fig. 51, if the height of the lumbar assembly 300 is set at an intermediate level (i.e., the same as Fig. 49), and a user leans back, the four-bar linkage defined by links and the structures 502, 522, 542, 558 and pivot points 516, 518, 540, 556 will shift (as described above) from the configuration of Fig. 49 to the configuration of Fig 51. This, in turn, causes an increase in the distance between the pivot point 586 and the cam surface 598. This causes an increase in the angle ∅ from about 49.5° (Fig. 49) to about 59.9° (Fig. 51). As the spring rotates towards an open position, some of the energy stored in the spring is transferred into the back shell 216, thereby causing the degree of curvature of the lumbar portion 220 of the back shell 216 to become greater. In this way, the back control link 584, the cam link 594, and the torsion springs 600 provide for greater curvature of the lumbar portion 242 to reduce curvature of a user's back as the user leans back in the chair.
Also, as the chair tilts from the position of Fig. 49 to the position of Fig. 51, the distance D between the lumbar region or portion 242 and the seat 16 increases from 174mm to 234mm. A dimension D₁ between the lumbar portion 242 of back shell 216 and the back frame structure 200 also increases as the back 18 tilts from the position of Fig. 49 to the position of Fig. 51. Thus, although the distance D increases somewhat, the increase in the dimension D₁ reduces the increase in dimension D because the lumbar portion 242 of the back shell 216 is shifted forward relative to the back frame 200 during recline.
Referring again to Fig. 49, a spine 604 of a seated user 606 tends to curve forwardly in the lumbar region 608 by a first amount when a user 606 is seated in an upright position. As a user 606 leans back from the position of Fig. 49 to the position of Fig. 51, the curvature of the lumbar region 608 tends to increase, and the user's spine 604 will also rotate somewhat about hip joint 610 relative to a user's femur 612. The increase in the dimension D and the increase in curvature of the lumbar portion 242 of the back shell 216 simultaneously ensure that the user's hip joint 610 and the femur 612 do not slide on the seat 16, and also accommodate curvature of the lumbar region 608 of a user's spine 604.
As discussed above, Fig. 50 shows the back 18 of the chair in an upright position with the lumbar portion 242 of the back shell 216 adjusted to a flat position. If the chair back 18 is tilted from the position of Fig. 50 to the position of Fig. 52, the back control link 584 and the cam link 594 both rotate in a clockwise direction. However, the cam link 594 rotates at a somewhat higher rate, and the angle ∅ therefore changes from 31.4° to 35.9°. The distance D changes from 202mm to 265mm, and the angle ∅₁ changes from 24.2° to 24.1°.
With further reference to Fig. 52A, if the chair back 18 is reclined, and the lumbar adjustment is set high, the angle ∅ is 93.6°, and the distance D is 202mm.
Thus, the back shell 216 curves as the chair back 18 is tilted rearwardly. However, the increase in curvature in the lumbar portion 242 from the upright to the reclined position is significantly greater if the curvature is initially adjusted to a higher level. This accounts for the fact that the curvature of a user's back does not increase as much when a user reclines if the user's back is initially in a relatively flat condition when seated upright. Restated, if a user's back is relatively straight when in an upright position, the user's back will remain relatively flat even when reclined, even though the degree of curvature will increase somewhat from the upright position to the reclined position. Conversely, if a user's back is curved significantly when in the upright position, the curvature of the lumbar region will increase by a greater degree as the user reclines relative to the increase in curvature if a user's back is initially relatively flat.
A pair of spring assemblies 614 (Figs. 43 and 44) bias the back assembly 18 (Fig. 4) from the reclined position F towards the upright position E. As best illustrated in Fig. 45, each spring assembly 614 includes a cylindrically-shaped housing 616 having a first end 618 and a second end 620. Each spring assembly 614 further includes a compression coil spring 622, a first coupler 624 and a second coupler 626. In the illustrated example, the first coupler 624 is secured to the first end 618 of the housing 616, while the second coupler 626 is secured to a rod member 628 that extends through the coil spring 622. A washer 630 is secured to a distal end of the rod member 628 and abuts an end of the coil spring 622, while the opposite end of the coil spring 622 abuts the second end 620 of the housing 616. The first coupler 624 is pivotably secured to the back support structure 542 by a pivot pin 632 for pivoting movement about a pivot point 634, wherein the pivot pin 632 is received within pivot apertures 636 of the back support structure 542, while the second coupler 626 is pivotably coupled to a moment arm shift assembly 638 (Figs. 53-55) by a shaft 640 for pivoting about a pivot point 642. The moment arm shift assembly 638 is adapted to move the biasing or spring assembly 614 from a low tension setting (Fig. 57A) to a high tension setting (Fig. 58A) wherein the force exerted by the biasing assembly 614 on the back assembly 18 is increased relative to the low-tension setting.
As illustrated in Figs. 53-56, the moment arm shift assembly 638 includes an adjustment assembly 644, a moment arm shift linkage assembly 646 operably coupling the control input assembly 500 to the adjustment assembly 644 and allowing the operator to move the biasing assembly 614 between the low and high tension settings, and an adjustment assist assembly 648 that is adapted to reduce the amount of input force required to be exerted by the user on the control input assembly 500 to move the moment arm shift assembly 638 from the low tension setting to the high tension setting, as described below.
The adjustment assembly 644 comprises a pivot pin 650 that includes a threaded aperture that threadably receives a threaded adjustment shaft 652 therein. The adjustment shaft 652 includes a first end 654 and a second end 656, wherein the first end 654 extends through the aperture 514 of the base structure 502 and is guided for pivotal rotation about a longitudinal axis by a bearing assembly 660. The pivot pin 650 is supported from the base structure 502 by a linkage assembly 662 (Fig. 44) that includes a pair of linkage arms 664 each having a first end 666 pivotably coupled to the second coupler 626 by the pivot pin 632 and a second end 668 pivotably coupled to the base structure 502 by a pivot pin 670 pivotably received within a pivot aperture 672 of the base structure 502 for pivoting about a pivot point 674, and an aperture 675 that receives a respective end of the pivot pin 650. The pivot pin 650 is pivotably coupled with the linkage arms 664 along the length thereof.
The moment arm shift linkage assembly 638 includes a first drive shaft 676 extending between the control input assembly 500 and a first beveled gear assembly 678, and a second drive shaft 680 extending between and operably coupling the first beveled gear assembly 678 with a second beveled gear assembly 682, wherein the second beveled gear assembly 682 is connected to the adjustment shaft 652. The first drive shaft 676 includes a first end 684 operably coupled to the control input assembly 500 by a first universal joint assembly 686, while the second end 688 of the first drive shaft 676 is operably coupled to the first beveled gear assembly 678 by a second universal joint assembly 690. In the illustrated example, the first end 684 of the first drive shaft 676 includes a female coupler portion 692 of the first universal joint assembly 686, while the second end 688 of the first drive shaft 676 includes a female coupler portion 694 of the second universal joint assembly 690. The first beveled gear assembly 678 includes a housing assembly 696 that houses a first beveled gear 698 and a second beveled gear 700 therein. As illustrated, the first beveled gear 698 includes an integral male coupler portion 702 of the second universal joint assembly 690. The first end 706 of the second drive shaft 680 is coupled to the first beveled gear assembly 678 by a third universal joint assembly 704. The first end 706 of the second drive shaft 680 includes a female coupler portion 708 of the third universal joint assembly 704. The second beveled gear 700 includes an integral male coupler portion 710 of the third universal joint assembly 704. A second end 712 of the second drive shaft 680 includes a plurality of longitudinally extending splines 714 that mate with corresponding longitudinally extending splines (not shown) of a coupler member 716. The coupler member 716 couples the second end 712 of the second drive shaft 680 with the second beveled gear assembly 682 via a fourth universal joint assembly 718. The fourth universal joint assembly 718 includes a housing assembly 720 that houses a first beveled gear 722 coupled to the coupler member 716 via the fourth universal joint assembly 718, and a second beveled gear 724 fixed to the second end 656 of the adjustment shaft 652. The coupler member 716 includes a female coupler portion 726 that receives a male coupler portion 728 integral with the first beveled gear 722.
In assembly, the adjustment assembly 644 (Figs. 53 and 54) of the moment arm shift assembly 638 is operably supported by the base structure 502, while the control input assembly 500 (Fig. 42) is operably supported by the control input assembly mounting portion 536 (Fig. 44) of the seat support structure 522. As a result, the relative angles and distances between the control input assembly 500 and the adjustment assembly 644 of the moment arm shift assembly 638 change as the seat support structure 522 is moved between the fully upright position G and the fully reclined H. The third and fourth universal joint assemblies 704, 718, and the arrangement of the spline 714 and the coupler 716 cooperate to compensate for these relative changes in angle and distance.
The moment arm shift assembly 638 (Figs. 53 and 54) functions to adjust the biasing assemblies 614 between the low-tension and high-tension settings (Figs. 57A-58B). Specifically, the biasing assemblies 614 are shown in a low-tension setting with the chair assembly 10 in an upright position in Fig. 57A, and the low-tension setting with the chair assembly 10 in a reclined position in Fig. 57B, while Fig. 58A illustrates the biasing assemblies 614 in the high-tension setting with the chair in an upright position, and Fig. 58B the biasing assemblies in the high-tension setting with the chair assembly 10 in the reclined position. The distance 730, as measured between the pivot point 642 and the second end 620 of the housing 616 of the spring assembly 614, serves as a reference to the amount of compression exerted on the spring assembly 614 when the moment arm shift assembly 638 is positioned in the low-tension setting and the chair assembly 10 is in the upright position. The distance 730 (Fig. 58A) comparatively illustrates the increased amount of compressive force exerted on the spring assembly 614 when the moment arm shift assembly 638 is in the high-tension setting and the chair assembly 10 is in the upright position. The user adjusts the amount of force exerted by the biasing assemblies 614 on the back support structure 542 by moving the moment arm shift assembly 638 from the low-tension setting to the high-tension setting. Specifically, the operator, through an input to the control input assembly 500, drives the adjustment shaft 652 of the adjustment assembly 644 in rotation via the moment arm shift linkage assembly 646, thereby causing the pivot shaft 650 to travel along the length of the adjustment shaft 654, thus changing the compressive force exerted on the spring assemblies 614 as the pivot shaft 650 is adjusted with respect to the base structure 502. The pivot shaft 650 travels within a slot 732 located within a side plate member 734 attached to an associated side wall 508 of the base structure 502. It is noted that when the moment arm shift assembly 638 is in the high-tension setting and the chair assembly 10 is in the upright position the distance 730' is greater than the distance 730 when the moment arm shift assembly 638 is in the low-tension setting and the chair assembly 10 is in the upright position, thereby indicating that the compressive force as exerted on the spring assemblies 614, is greater when the moment arm shift is in the high-tension setting as compared to a low-tension setting. Similarly, the distance 736' (Fig. 58B) is greater than the distance 736 (Fig. 57B), resulting in an increase in the biasing force exerted by the biasing assemblies 614 and forcing the back assembly 18 from the reclined position towards the upright position. It is noted that the change in the biasing force exerted by the biasing assemblies 614 corresponds to a change in the biasing torque exerted about the second pivot point 518, and that in certain configurations, a change in the biasing torque is possible without a change in the length of the biasing assemblies 614 or a change in the biasing force.
Figure 59 is a graph of the amount of torque exerted about the second pivot point 518 forcing the back support structure 542 from the reclined position towards the upright position as the back support structure 542 is moved between the reclined and upright positions. In the illustrated example, the biasing assemblies 614 exert a torque about the second pivot point 518 of about 73.67Nm (652 inch-pounds) when the back support structure 542 is in the upright position and the moment arm shift assembly 638 is in the low tension setting, and of about 105.41Nm (933 inch-pounds) when the back support structure 542 is in the reclined position and the moment arm shift assembly 638 is in the low tension setting, resulting in a change of approximately 43%. Likewise, the biasing assemblies 614 exert a torque about the second pivot point 518 of about 166.09Nm (1.47E+03 inch-pounds) when the back support structure 542 is in the upright position and the moment arm shift assembly 638 is in the high tension setting, and of about 291.50Nm (2.58E+03 inch-pounds) when the back support structure 542 is in the reclined position and the moment arm shift assembly 638 is in the high tension setting, resulting in a change of approximately 75%. This significant change in the amount of torque exerted by the biasing assemblies 614 between the low tension setting and the high tension setting of the moment arm shift assembly 638 as the back support structure 542 is moved between the upright and reclined positions allows the overall chair assembly 10 to provide proper forward back support to users of varying height and weight.
The adjustment assist assembly 648 (Figs. 53 and 54) assists an operator in moving the moment arm shift assembly 638 from the high-tension setting to the low-tension setting. The adjustment assist assembly 648 includes a coil spring 738 secured to the front wall 504 of the base structure 502 by a mounting structure 740, and a catch member 742 that extends about the shaft 632 fixed with the linkage arms 664, and that includes a catch portion 744 defining an aperture 746 that catches a free end 748 of the coil spring 738. The coil spring 738 exerts a force F on the catch member 742 and the shaft 632 in an upward vertical direction, and on the shaft 632 that is attached to the linkage arms 664, thereby reducing the amount of input force the user must exert on the control input assembly 500 to move the moment arm shift assembly 638 from the low-tension setting to the high-tension setting.
As noted above, the seat assembly 16 (Fig. 3) is longitudinally shiftable with respect to the control assembly 14 between a retracted position C and an extended position D. As best illustrated in Figs. 60 and 61, a direct drive assembly 1562 includes a drive assembly 1564 and a linkage assembly 1566 that couples the control input assembly 500 with the drive assembly 1564, thereby allowing a user to adjust the linear position of the seat assembly 16 with respect to the control assembly 14. In the illustrated example, the seat support plate 32 (Fig. 42) includes the C-shaped guiderails 38 which wrap about and slidably engage corresponding guide flanges 1570 of a control plate 1572 of the control assembly 14. A pair of C-shaped, longitudinally extending connection rails 1574 are positioned within the corresponding guiderails 38 and are coupled with the seat support plate 32. A pair of C-shaped bushing members 1576 extend longitudinally within the connection rails 1574 and are positioned between the connection rails 1574 and the guide flanges 1570. The drive assembly 1564 includes a rack member 1578 having a plurality of downwardly extending teeth 1580. The drive assembly 1564 further includes a rack guide 1582 having a C-shaped cross-sectional configuration defining a channel 1584 that slidably receives the rack member 1578 therein. The rack guide 1582 includes a relief 1586 located along the length thereof that matingly receives a bearing member 1588 therein, wherein the bearing member 1588 as illustrated in dashed line shows the assembly alignment between the bearing member 1588 and the relief 1586 of the rack guide 1582, and further wherein the bearing member as illustrated in solid line shows the assembly alignment between the bearing member 1588 and the rack member 1578. Alternatively, the bearing member 1588 may be formed as an integral portion of the rack guide 1582. The drive assembly 1564 further includes a drive shaft 1590 having a first end 1592 universally coupled with the control input assembly 500 and the second end 1594 having a plurality of radially-spaced teeth 1596. In assembly, the seat support plate 32 is slidably coupled with the control plate 1572 as described above, with the rack member 1578 being secured to an underside of the seat support plate 32 and the rack guide 1582 being secured within an upwardly opening channel 1598 of the control plate 1572. In operation, an input force exerted by the user to the control input assembly 500 is transferred to the drive assembly 1564 via the linkage assembly 1566, thereby driving the teeth 1596 of the drive shaft 1590 against the teeth 1580 of the rack member 1578 and causing the rack member 1578 and the seat support plate 32 to slide with respect to the rack guide 1582 and the control plate 1572.
With further reference to Figs. 62-64, the chair assembly 10 includes a height adjustment assembly 1600 that permits vertical adjustment of seat 16 and back 18 relative to the base assembly 12. Height adjustment assembly 1600 includes the pneumatic cylinder 28 that is vertically disposed in central column 26 of base assembly 12 in a known manner.
A bracket structure 1602 is secured to the housing or base structure 502, and an upper end portion 1604 of the pneumatic cylinder 28 is received in an opening 1606 (Fig. 64) of the base structure 502 in a known manner. The pneumatic cylinder 28 includes an adjustment valve 1608 that can be shifted down to release the pneumatic cylinder 28 to provide for height adjustment. A bell crank 1610 has an upwardly extending arm 1630 and a horizontally extending arm 1640 that is configured to engage the release valve 1608 of the pneumatic cylinder 28. The bell crank 1610 is rotatably mounted to the bracket 1602. A cable assembly 1612 operably interconnects the bell crank 1610 with an adjustment wheel/lever 1620. The cable assembly 1612 includes an inner cable 1614 and an outer cable or sheath 1616. The outer sheath 1616 includes a spherical ball fitting 1618 that is rotatably received in a spherical socket 1622 formed in the bracket 1602. A second ball fitting 1624 is connected to an end 1626 of the inner cable 1614. A second ball fitting 1624 is rotatably received in a second spherical socket 1628 of the upwardly extending arm 1630 of the bell crank 1610 to permit rotational movement of the cable end during height adjustment.
A second or outer end portion 1632 of the inner cable 1614 wraps around the wheel 1620, and an end fitting 1634 is connected to the inner cable 1614. A tension spring 1636 is connected to the end fitting 1634 and to the seat structure at point 1638. The spring 1636 generates tension on the inner cable 1614 in the same direction that the cable 1614 is shifted to rotate the bell crank 1610 when the valve 1608 is being released. Although the spring 1636 does not generate enough force to actuate the valve 1608, the spring 1636 does generate enough force to bias the arm 1640 of the bell crank 1610 into contact with the valve 1608. In this way, lost motion or looseness that could otherwise exist due to tolerances in the components is eliminated. During operation, a user manually rotates the adjustment wheel 1620, thereby generating tension on the inner cable 1614. This causes the bell crank 1610 to rotate, causing the arm 1640 of the bell crank 1610 to press against and actuate the valve 1608 of the pneumatic cylinder 28. An internal spring (not shown) of the pneumatic cylinder 28 biases the valve 1608 upwardly, causing the valve 1608 to shift to a non-actuated position upon release of the adjustment wheel 1620.
The control input assembly 500 (Figs. 42 and 65-67) comprises a first control input assembly 1700 and a second control input assembly 1702 each adapted to communicate inputs from the user to the chair components and features coupled thereto, and housed within a housing assembly 1704. The control input assembly 500 includes an anti-back drive assembly 1706, an overload clutch assembly 1708, and a knob 1710. The anti-back drive mechanism or assembly 1706 that prevents the direct drive assembly 1562 (Figs. 60 and 61) and the seat assembly 16 from being driven between the retracted and extended positions C, D without input from the control assembly 1700. The anti-back drive assembly 1706 is received within an interior 1712 of the housing assembly 1704 and includes an adaptor 1714 that includes a male portion 1716 of a universal adaptor coupled to the second end 1594 of the drive shaft 1590 (Fig. 61) at one end thereof, and including a spline connector 1717 at the opposite end. A cam member 1718 is coupled with the adaptor 1714 via a clutch member 1720. Specifically, the cam member 1718 includes a spline end 1722 coupled for rotation with the knob 1710, and a cam end 1724 having an outer cam surface 1726. The clutch member 1720 (Fig. 66B) includes an inwardly disposed pair of splines 1723 that slidably engage the spline connector 1717 having a cam surface 1730 that cammingly engages the outer cam surface 1726 of the cam member 1718, as described below. The clutch member 1720 has a conically-shaped clutch surface 1719 that is engagingly received by a locking ring 1732 that is locked for rotation with respect to the housing assembly 1704 and includes a conically-shaped clutch surface 1721 corresponding to the clutch surface 1719 of the clutch member 1720, and cooperating therewith to form a cone clutch. A coil spring 1734 biases the clutch member 1720 towards engaging the locking ring 1732.
Without input, the biasing spring 1734 forces the conical surface of the clutch member 1720 into engagement with the conical surface of the locking ring 1732, thereby preventing the "back drive" or adjustment of the seat assembly 16 between the retracted and extended positions C, D, simply by applying a rearward or forward force to the seat assembly 16 without input from the first control input assembly 1700. In operation, an operator moves the seat assembly 16 between the retracted and extended positions C, D by actuating the direct drive assembly 1562 via the first control input assembly 1700. Specifically, the rotational force exerted on the knob 1710 by the user is transmitted from the knob 1710 to the cam member 1718. As the cam member 1718 rotates, the outer cam surface 1726 of the cam member 1718 acts on the cam surface 1730 of the clutch member 1720, thereby overcoming the biasing force of the spring 1734 and forcing the clutch member 1720 from an engaged position, wherein the clutch member 1720 disengages the locking ring 1732. The rotational force is then transmitted from the cam member 1718 to the clutch member 1720, and then to the adaptor 1714 which is coupled to the direct drive assembly 1562 via the linkage assembly 1566.
It is noted that a slight amount of tolerance within the first control input assembly 1700 allows a slight movement (or "slop") of the cam member 1718 in the linear direction and rotational direction as the clutch member 1720 is moved between the engaged and disengaged positions. A rotational ring-shaped damper element 1736 comprising a thermoplastic elastomer (TPE), is located within the interior 1712 of the housing 1704, and is attached to the clutch member 1720. In the illustrated example, the damping element 1736 is compressed against and frictionally engages the inner wall of the housing assembly 1704.
The first control input assembly 1700 also includes a second knob 1738 adapted to allow a user to adjust the vertical position of the chair assembly between the lowered position A and the raised position B, as described below.
The second control input assembly 1702 is adapted to adjust the tension exerted on the back assembly 18 during recline, and to control the amount of recline of the back assembly 18. A first knob 1740 is operably coupled to the moment arm shift assembly 638 by the moment arm shift linkage assembly 646. Specifically, the second control input assembly 1702 includes a male universal coupling portion 1742 that couples with the female universal coupler portion 692 (Figs. 53 and 55) of the shaft 676 of the moment arm shift linkage assembly 646.
A second knob 1760 is adapted to adjust the amount of recline of the back assembly 18 via a cable assembly 1762 operably coupling the second knob 1760 to a variable back stop assembly 1764 (Fig. 67). The cable assembly 1762 includes a first cable routing structure 1766, a second cable routing structure 1768 and a cable tube 1770 extending therebetween and slidably receiving an actuator cable 1772 therein. The cable 1772 includes a distal end 1774 that is fixed with respect to the base structure 502, and is biased in a direction 1776 by a coil spring 1778. The variable back stop assembly 1764 includes a stop member 1780 having a plurality of vertically graduated steps 1782, a support bracket 1784 fixedly supported with respect to the seat assembly 16, and a slide member 1786 slidably coupled to the support bracket 1784 to slide in a fore-to-aft direction 1788, and fixedly coupled to the stop member 1780 via a pair of screws 1790. The cable 1772 is clamped between the stop member 1780 and the slide member 1786 such that longitudinal movement of the cable 1772 causes the stop member 1780 to move in the fore-and-aft direction 1788. In operation, a user adjusts the amount of back recline possible by adjusting the location of the stop member 1780 via an input to the second knob 1760. The amount of back recline available is limited by which select step 1782 of the stop member 1780 contacts a rear edge 1792 of the base structure 502 as the back assembly 18 moves from the upright position toward the reclined position.
The reference numeral 10e (Fig. 68) generally designates the embodiment according to the invention of the chair assembly or seating arrangement. Since the seating arrangement 10e is similar to the previously described seating arrangement or chair assembly 10, similar parts appearing in Figs. 1 and 2 and Fig. 68 respectively are represented by the same, corresponding reference numeral, except for the suffix "e" in the numerals of the latter. In the illustrated example, the seating arrangement 10e includes a headrest assembly 2000 pivotably coupled with the back assembly 18e. The headrest assembly 2000 includes a support assembly 2002 and a headrest member 2004. As best illustrated in Figs. 69 and 70A, the support assembly 2002 includes a support member 2006 pivotably coupled to the back assembly 18e via a first hinge arrangement 2008. The support member 2006 has a generally U-shaped configuration including a laterally extending base portion 2010 and a pair of upwardly extending arm portions 2012. Each arm portion includes a vertical portion 2014 and a distal end portion 2016 that extends upwardly and slightly forward from the associated vertical portion 2014. The first hinge arrangement 2008 includes a pair of hinges 2018 that pivotably couple the support member 2006 to the back rest assembly 18e for rotation about a laterally-extending first pivot axis 2020 in the directions 2022. Each hinge 2018 comprises a friction-lock type hinge, wherein the rotational position of the support member 2006 with respect to the back assembly 18e is held in position by the friction within the hinges 2018. Specifically, the hinges 2018 couple the support member 2006 to an upper portion 218e of the back shell 216e (Fig. 71). In the illustrated example, the back shell 216e includes a recess 2021 and the comfort member 298e includes a recess 2023 each for receiving the base portion 2010 therein. The support assembly 2002 further includes a support cover 2025 for covering a front of the base portion 2010, while a rear cover 2027 shrouds the back of the back shell 216e. In adjustment, the friction within the hinges 2018 is overcome by a user applying a sufficient force to the headrest assembly 2000. After adjustment, the force exerted by the user is removed and the friction within the hinges 2018 holds the support member 2006 in the rotational position selected. It is noted that no external or separately releasable locking assemblies hold or secure the support member 2006 in a rotational position with respect to the back assembly 18e.
The support assembly 2000 further includes a second hinge arrangement 2024 that includes a guide member 2026 having a planar body portion 2028 and a pair of tubular end portions 2030 each having an outwardly opening aperture 2032. The second hinge arrangement 2024 further includes a pair of friction-lock type hinge arrangements 2033 (Fig. 72) that rotationally couple the headrest member 2004 to the support member 2006 for rotation about a laterally-extending second pivot axis 2034 in the directions 2036 (Fig. 69). Each hinge arrangement 2033 (Fig. 72) includes a hinge 2038 including a first end 2040 press fit and secured from rotation within the associated aperture 2032 of one of the end portions 2030 of the guide member 2026, and a second end 2042 press fit and secured from rotation within an aperture 2044 of one of the distal end portions 2016 of the arm portions 2012 of the support member 2006. The hinge arrangements 2033 which allow the headrest member 2004 to be pivoted with respect to the support member 2006 about the second pivot axis 2034. As noted above, each of the hinge arrangements 2033 comprises a friction-lock type hinge, wherein the rotational position of the headrest member 2004 is held in position by the friction within the hinge arrangements 2033. In adjustment, the friction within the hinge arrangements 2033 is overcome by the user applying sufficient force to the headrest member 2004. After adjustment, the force exerted by the user is removed and the friction within the hinge arrangements 2033 holds the headrest member 2004 in the rotation position selected. It is noted that no external or separately releasably locking assemblies hold or secure the headrest member 2004 in a rotational position with respect to the support member 2006. End caps 2046 are placed within the ends of the apertures 2044. The dual-pivoting adjustment that allows pivoting and repositioning of the headrest member 2004 and support member 2006 about the first pivot axis 2020 and the second pivot axis 2034 allows the headrest to be repositioned in numerous and various positions and orientations relative to the back assembly 18e and a person seated within the seating arrangement 10e, as further described below. Alternatively, the headrest assembly may include a support member having a single arm portion and/or a single hinge coupling the support member to the back rest assembly and/or a single hinge coupling the headrest member to the support member.
The headrest member 2004 is further vertically adjustably supported by the support member 2006 for adjustment in the directions 2047. In a first embodiment, the headrest member 2004 (Fig. 70A) includes a frame member 2048, a subframe member 2050 releasably coupled to the frame member 2048, and a mesh fabric cover 2052 attached to the frame member 2048 by the subframe member 2050. Although a mesh fabric cover 2052 is included in the present example, it is noted that non-mesh fabric and other materials may also be utilized. The cover 2052 includes a forwardly facing support surface 2054 configured to support the head and/or neck of a seated user, and a wrapped edge 2056 extending rearwardly from the support surface 2054. A pair of horizontal stiles or attachment strips 2058 are positioned and secured along the top and bottom of the wrapped edge 2056, while a pair of vertical stiles or attachment strips 2059 are positioned and secured along the sides of the wrapped edge 2056. In assembly, the wrapped edge 2056 (Fig. 73) of the cover 2052 is wrapped about an outer peripheral edge of the subframe member 2050, and the attachment strips 2058 are coupled to a rear surface of the subframe member 2050. As best illustrated in Figs. 73-75, the horizontal attachment strips 2058 each have an arrow-shaped cross-sectional configuration including an expanded head 2061 that engages a plurality of flat tabs 2063 and a plurality of hook-shaped tabs 2065 spaced along the upper and lower edges of the subframe 2050, while the vertical attachment strips 2059 engage a plurality of flat tabs 2065 spaced along the sides of the subframe 2058. The vertical attachment strips 2059 are held in engagement with the flat tabs 2065 by the tension in the mesh fabric cover 2052, and may be held between the tabs 2065 and a peripheral wall 2049. The subframe member 2050 is then snappingly, releasably coupled to the frame member 2048 such that the wrapped edge 2056 and attachment strips 2058 are sandwiched and hidden between the subframe member 2050 and the frame member 2048.
In a second embodiment, the subframe 2050 and the mesh fabric cover 2052 of the first embodiment illustrated in Fig. 70A may be replaced with an upholstery ring 2051 (Fig. 70B), a foam member 2053 and an outer fabric cover 2055. In assembly, a plurality of attachment strips 2057 secure the fabric cover 2055 to the upholstery ring 2051 with the foam member 2053 sandwiched between the cover 2055 and the ring 2051. The ring 2051 is then attached to the frame 2048 such that the attachment strips 2057 and the edges of the fabric cover 2052 are sandwiched between the upholstery ring 2051 and the frame 2048.
The frame member 2048 includes an outer peripherally extending frame portion 2060 to which the subframe member 2050 is attached, and a vertically extending, forwardly convex, arcuately-shaped central portion 2062. The central portion 2062 (Fig. 70) includes a vertically extending elongated slot 2070, a first set of rearwardly-facing, vertically-spaced tabs 2072 and a second set of rearwardly-facing, vertically-spaced tabs 2074 spaced across the slot 2070 from the first set of tabs 2072. It is noted that the individual tabs of the first set of tabs 2072 are vertically offset from the individual tabs of the second set of tabs 2074. A pair of leaf springs 2076 are secured to the planar portion 2028 of the guide member 2026 by a pair of fastening portions 2078 located at the ends thereof. Each spring 2076 further includes an engagement portion 2080 located between the fastening portions 2078 and biased towards the first and second sets of the tabs 2072, 2074. An attachment member 2082 is attached to the guide member 2026 by a pair of screws 2086 such that the central portion 2062 is slidably sandwiched between the guide member 2026 and the attachment member 2082 and the sliding motion is guided by a shim 2085 positioned with the slot 2070. A cover 2083 is snapped to and encloses the back of the central portion 2062.
In adjustment, a user adjusts the headrest member 2004 with respect to the support assembly 2002 by applying an upward or downward force to the headrest member 2004, thereby vertically adjusting the headrest member 2004 in the vertical direction 2047 as well as pivoting the headrest member 2004 about a pivot area 2079 spaced from the headrest member 2004 and the support assembly 2002. The headrest member 2004 is held in a selected vertical position by engagement of the engagement portion 2080 of one of the leaf springs 2028 with the associated set of tabs 2072, 2074. As noted above, the tabs of the first and second set of tabs 2072, 2074 are vertically offset from one another such that only one set of tabs is engaged by the springs 2076, thereby increasing the effective vertical adjustability of the headrest member 2004. The incremental offset adjustability of the headrest member 2004 as provided by the vertically offset tables 2072, 2074 may alternatively be provided by vertically offsetting the springs 2076 from one another while the tabs 2072, 2074 are aligned with one another. In another embodiment, the tabs 2072, 2074 may be vertically offset from one another and the springs 2076 are vertically offset from one another.
The dual-pivoting adjustment and vertical adjustability of the headrest assembly 2000, allows the headrest assembly 2000 to be positioned between a wide variety of locations and assume numerous configurations to accommodate a wide variety of users in the manner illustrated in Figs. 78A-78K. For example, the headrest assembly 2000 may be adjusted between a forward position such as that shown in Fig. 78I, wherein the support assembly 2002 is rotated to a forward position with respect to the back assembly 18E and the headrest member 2004 is vertically adjusted to a lowered position with respect to the support assembly 2002, and a rearward position such as that shown in Fig. 78J, wherein the headrest member 2004 is vertically adjusted to an extreme raised position with respect to the support assembly 2002 and the support assembly 2002 is rotated to a rearward position with respect to the back assembly 18E. In these and other embodiments, the headrest member 2004 may rotate about the support assembly 2002 such that it comes into physical contact with support assembly 2002 or back rest assembly 18e. For example, in the position illustrated in Fig. 78I, the lower edge (as positioned) of headrest member 2004 may come into contact with a front surface of the back rest assembly 18e, while in the position illustrated in Fig. 78K, the lower edge (as positioned) of headrest member 2004 may come into contact with a rear surface of the back rest assembly 18e or the support assembly 2002.
In some embodiments, one or more stops may be built into the back assembly 18E, the support assembly 2002, and/or the headrest assembly 2000 to limit certain positions. For example, stop 2100 (Fig. 78K) may be provided to prevent the support assembly 2002 from rotating beyond a rearward horizontal orientation. Similarly, a stop 2102 (Fig. 78G) may be provided to prevent the support assembly 2002 from rotating forward of a chosen position.
In the foregoing description, it will be readily appreciated by those skilled in the art that alternative combinations of the various components and elements of the various embodiments and modifications to the various embodiments may be made without departing when the concept is disclosed, such as applying the concepts as disclosed herein to vehicle seating, stadium seating, home seating, theater seating and the like. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.

Claims

An office chair seating arrangement (10e) comprising:
a headrest assembly (2000) coupled to the seating arrangement (10e), the headrest assembly (2000) comprising:
a support arrangement (2002) pivotably coupled to a back assembly (18e) of the seating arrangement (10e) for pivoting movement about a first pivot axis (2020) where the back assembly is configured to support the back of a seated user;

a headrest member (2004) pivotably coupled directly to the support arrangement (2002) for pivoting movement about a second pivot axis (2034) that is spaced from the first pivot axis (2020); and

a sliding arrangement (2062, 2083) coupling the headrest member (2004) to the support arrangement (2002), and configured to allow sliding vertical adjustment of the headrest member (2004) with respect to the support arrangement (2002) along an arcuate path, wherein:

the seating arrangement further comprises:
a seat assembly (16e) adapted to support a user; and

the back assembly (18e) operably coupled to the seat assembly (16e) and adapted to support a user, where the support arrangement (2002) of the headrest assembly (2000) is pivotably coupled to the back assembly (18e).
The office chair seating arrangement (10e) of claim 1, wherein the sliding arrangement (2062, 2083) is configured such that the headrest member (2004) pivots about a pivot area spaced from at least one of the headrest member (2004) and the support arrangement (2002) as the headrest member (2004) is vertically adjusted by the sliding arrangement (2062, 2083).
The office chair seating arrangement (10e) of claim 2, wherein the sliding arrangement (2062, 2083) is configured such that the headrest member (2004) pivots about the pivot area that is spaced from the headrest member (2004) and the support arrangement (2002) as the headrest member (2004) is vertically adjusted by the sliding arrangement (2062, 2083).
The office chair seating arrangement (10e) of any of claims 1-3, wherein a distance between the first pivot axis (2020) and the second pivot axis (2034) remains substantially constant as the headrest member (2004) is vertically adjusted with respect to the back assembly (18e).
The office chair seating arrangement (10e) of any of claims 1-4, wherein the support arrangement (2002) includes a first friction hinge arrangement (2018) configured to pivotably couple the support arrangement (2002) to the back assembly (18e).
The office chair seating arrangement (10e) of claim 5, wherein the headrest member (2004) is pivotably coupled to the support arrangement (2002) by a second friction hinge arrangement (2024).
The office chair seating arrangement (10e) of any of claims 1-6, wherein the headrest member (2004) includes an arcuately-shaped track portion (2062, 2083) that is slidably engaged by the support arrangement (2002).
The office chair seating arrangement (10e) of any of claims 1-7, wherein the support arrangement (2002) includes a spring-biased engagement member (2080) that frictionally engages the headrest assembly (2004) such that the headrest assembly may be selectively adjusted between a plurality of vertical positions with respect to the back assembly (18e).
The office chair seating arrangement (10e) of claim 8, wherein the headrest member (2004) includes a plurality of detents (2072) spaced from one another and selectively engagable by the spring-biased engagement member (2080) to retain the headrest member (2004) at the vertical positions.
The office chair seating arrangement (10e) of claim 9, wherein the plurality of detents (2072) is one of a pair of plurality of detents (2072, 2074) that includes a first plurality of detents (2072) and a second plurality of detents (2074), the detents of the first plurality of detents (2072) offset from the detents of the second plurality of detents (2074) such that the engagement member (2080) alternately engages the first plurality of detents (2072) and the second plurality of detents (2074) as the headrest member (2004) is vertically adjusted.
The office chair seating arrangement (10e) of any one of claims 1-10, wherein the headrest member (2004) may be pivoted about the second pivot axis (2034) separately from the support arrangement (2002) being pivoted about the first pivot axis (2020).