US20240156265A1

US20240156265A1 - Seating structure having a support pocket

Info

Publication number: US20240156265A1
Application number: US18/508,030
Authority: US
Inventors: John F. Aldrich; Ethan McGraw
Original assignee: MillerKnoll Inc
Current assignee: MillerKnoll Inc
Priority date: 2022-11-11
Filing date: 2023-11-13
Publication date: 2024-05-16
Also published as: WO2024103065A1

Abstract

A seating structure including a frame, a suspension member, and a support pad. The frame defines an opening. The suspension member is coupled to the frame and spans over the opening. The suspension member is configured to engage a user and has a three-dimensional topography independent of the frame and relative to a straight reference line that extends between opposing sides of the frame.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/424,743, filed Nov. 11, 2022, the entire contents of which are incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to seating structures such as task or office chairs. More particularly, the present invention relates to seating structures having suspension members or materials.

SUMMARY

In one aspect, the disclosure provides a seating structure including a frame and a suspension member. The frame defines an opening. The suspension member is coupled to the frame and spans over the opening. The suspension member is configured to engage a user and has a three-dimensional topography independent of the frame and relative to a straight reference line that extends between opposing sides of the frame.
In another aspect, the disclosure provides a seating structure including a base, a backrest supported by the base, a suspension member, a pocket defined in the suspension member, and a support pad. The backrest includes a frame that defines an opening. The suspension member is coupled to the frame and spans over the opening. The pocket is defined in the suspension member. The support pad is received in the pocket.
In another aspect, the disclosure provides a seating structure including a frame, a suspension member, and a support pad. The frame defines an opening. The suspension member is coupled to the frame and spans over the opening. The suspension member includes a first tensile member that provides a first tensile force in the suspension member and a second tensile member that provides a second tensile force in the suspension member. The support pad is supported on the suspension member between the first tensile member and the second tensile member.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a seating structure including a seat and a backrest according to some embodiments.

FIG. 2 is an enlarged view of a portion of a suspension material for use with the seating structure shown in FIG. 1 .

FIG. 3 is an enlarged view of a portion of another suspension material for use with the seating structure shown in FIG. 1 .

FIG. 4 is a schematic view of the backrest including pockets for the seating structure shown in FIG. 1 .

FIG. 5 is a rear view of the backrest.

FIG. 6 is a front view of the backrest.

FIG. 7A is a front view of a thoracic support pad for the backrest.

FIG. 7B is a front view of a lumbar support pad for the backrest.

FIG. 8 is schematic, side cross-sectional view of the backrest.

FIG. 9A is a cross-sectional view of the backrest of FIG. 6 taken along line A-A.

FIG. 9B is a cross-sectional view of the backrest of FIG. 6 taken along line B-B.

FIG. 10A is a front view of a suspension member including a pocket.

FIG. 10B is a rear view of the suspension member and pocket of FIG. 10A.

FIG. 11A is a front view of another suspension member including a pocket.

FIG. 11B is a rear view of the suspension member and pocket of FIG. 11A.

FIG. 12 is a front view of another suspension member including a pocket.

FIG. 13 is a front view of another suspension member including a pocket.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
Various exemplary embodiments are related to seating structures and methods of manufacturing seating structures. Seating structures may include any structure used to support a body of a user, for example, without limitation, task chairs, side chairs, sofas, airplane seats, vehicle seats, bicycle seats, boat seats, beds, dental and medical seats and beds, auditorium and educational seats, etc. It should be understood that the various methods and devices disclosed herein may be applied to seating structures other than a seat and/or backrest, including for example and without limitation armrests, headrests and other ergonomic positioning features. Although the illustrated embodiments are shown in connection with an office chair, other embodiments can include different configurations.
FIG. 1 shows an exemplary embodiment of a seating structure 10, such as a chair. The illustrated embodiment is only one example of a configuration of a chair. The chair may have other shapes and/or configurations. The seating structure 10 may also be a different type of furniture item, such as a bench, sofa, settee, chaise, ottoman, bed, cot, and the like. In the illustrated embodiment, the seating structure 10 is an office chair.
The seating structure 10 includes a seat 14, a backrest 18, and a base 22. In the illustrated embodiment, the seating structure 10 includes armrests 20. In other embodiments, the seating structure 10 may not include armrests. The base 22 includes a tilt mechanism 26, a support column 30 coupled to and supporting the tilt mechanism 26, and a base structure 34 coupled to and supporting the support column 30. In other embodiments, the seat 14 and/or backrest 18 may be rigidly coupled to the support column 30 or base 22. In the illustrated embodiment, the base 22 includes five feet 23 surrounding a central hub. Each of the feet 23 is coupled to a castor wheel 24. In some embodiments, the base 22 may include glides instead of castor wheels. In other embodiments, the base 22 may include a plurality of legs. In such embodiments, the support column 30 and/or the tilt mechanism 26 may be omitted.
The seat 14 includes a frame 38 a, a suspension member 42 a, and a carrier 46 a. The carrier 46 a retains the suspension member 42 a and connects to the frame 38 a. In other embodiments, the suspension member 42 a may be directly coupled to the frame 38 a. The frame 38 a defines an opening, and the suspension member 42 a spans over the opening. The suspension member 42 a is configured to engage and support a weight of a user. In some embodiments, the suspension member 42 a may be formed of a single jersey knit structure. In other embodiments, the suspension member 42 a may be formed of a double jersey knit structure. In further embodiments, the suspension member 42 a may be formed of both a single jersey and a double jersey knit structure. In yet further embodiments, the suspension member 42 a may be formed of another type of knit structure. In still other embodiments, the suspension member 42 a may be formed of a woven structure.
Likewise, the backrest 18 includes a frame 38 b, a suspension member 42 b, and a carrier 46 b. In some embodiments, only one suspension member and one frame may be used to form a continuous seat and backrest. In the illustrated embodiment, the carrier 46 b retains the suspension member 42 b and connects to the frame 38 b. The suspension member 42 b extends across the frame 38 b to support a user on the seating structure 10. In other embodiments, the suspension member 42 b may be directly coupled to the frame 38 b. The frame 38 b defines an opening, and the suspension member 42 b spans over the opening. The suspension member 42 b is configured to engage and support a back of a user. In some embodiments, the suspension member 42 b may be formed of a single jersey knit structure. In other embodiments, the suspension member 42 b may be formed of a double jersey knit structure. In further embodiments, the suspension member 42 b may be formed of both a single jersey and a double jersey knit structure. In yet further embodiments, the suspension member 42 b may be formed of another type of knit structure. In still other embodiments, the suspension member 42 b may be formed of a woven structure.
FIG. 2 illustrates a single jersey knit and tunnel inlay structures 50 a, 50 b of the suspension members 42 a, 42 b. Each single jersey knit structure 50 a, 50 b has one or more multifilaments 54 a, 54 b and one or more monofilaments 58 a, 58 b. In some embodiments, the single jersey knit structure may include a plurality of multifilaments. Additionally, the single jersey knit structure may include a plurality of monofilaments. Each of the multifilaments 54 a, 54 b forms a respective one of the jersey knit structures and has a plurality of courses extending in a course direction C and a plurality of wales extending in a wale direction W. The monofilaments 58 a, 58 b correspond to and are inlaid in a respective one of the courses. The monofilaments 58 a, 58 b extend in the course direction C. In the illustrated embodiment, every course includes an inlaid one of the monofilaments 58 a, 58 b. In some embodiments, only some of the courses may include an inlaid one of the monofilaments 58 a, 58 b. In some embodiments, the monofilaments 58 a, 58 b may be inlaid in the wales and may extend in the wale direction W.
FIG. 3 illustrates another knit structure 70 of a suspension member 74. The suspension member 74 is similar to the suspension members 42 a, 42 b discussed above and includes one or more multifilaments 78, 82 and one or more monofilaments 86. The suspension member 74 may be used to form either a seat or a backrest. Unlike the suspension member 42 discussed above, the suspension member 74 has a double jersey interlock knit structure with a tunnel inlay. The double jersey interlock structure is formed from one of each of the multifilaments 78, 82 and a monofilament 86 tunnel inlay forms a respective one of the jersey knit structures and has a plurality of courses extending in a course direction C and a plurality of wales extending in a wale direction W. The monofilaments 58 a, 58 b correspond to and are inlaid in a respective one of the courses. The monofilaments 58 a, 58 b extend in the course direction C. In the illustrated embodiment, every course includes an inlaid one of the monofilaments 58 a, 58 b. In some embodiments, only some of the courses may include an inlaid one of the monofilaments 58 a, 58 b. In some embodiments, the monofilaments 58 a, 58 b may be inlaid in the wales and may extend in the wale direction W.
As illustrated in FIG. 4 , the backrest 18 includes one or more pockets 90, 102 defined in the suspension member 42 b. The illustrated backrest 18 includes two pockets 90, 102. In other embodiments, the backrest 18 may include fewer or more pockets. For example, the backrest 18 may include a single pocket or may include three or more pockets. Each pocket 90, 102 is configured to receive an object, such as a support pad, to provide targeted support to a user in the seating structure 10. In the illustrated embodiment, the first pocket 90 is an upper pocket, and the second pocket 102 is a lower pocket such that the first pocket 90 and the second pocket 102 are spaced apart from each other. Each of the upper pocket 90 and the lower pocket 102 is configured to receive a support pad 94, 122 (FIGS. 7A and 7B), as will be described in more detail below. For example, the upper pocket 90 may receive a thoracic support pad 94, and the lower pocket 102 may receive a lumber support pad 122. The upper pocket 90 and the lower pocket 102 are formed in the suspension member 42 b between a top end 106 and a bottom end 110 of the backrest 18 and along the center of the suspension member 42 b. More specifically, the upper pocket 90 is located in the suspension member 42 b adjacent the top end 106 of the backrest 18. As such, the upper pocket 90 may be positioned between shoulder blades of a user supported in the seating structure 10. The lower pocket 102 is located in the suspension member 42 b between the upper pocket 90 and the bottom end 110 of the backrest 18. As such, the lower pocket 102 may be located adjacent to the lower spine of a user supported in the seating structure 10. In the other embodiments, the pockets 90, 102 may be located elsewhere within the periphery of the frame 38 b.
As illustrated in FIGS. 5 and 6 , the illustrated suspension member 42 b includes a first layer 114 and a second layer 118. In the illustrated embodiment, the first layer 114 is provided in front of the second layer 118 such that the first layer 114 faces and contacts a user supported in the seating structure 10, and the second layer 118 faces away from a user supported in the seating structure 10. The first layer 114 may also be referred to as a front layer, and the second layer 118 may also be referred to as a rear layer. The pockets 90, 102 are defined between the first layer 114 and the second layer 118. In some embodiments, the first and second layers 114, 118 may span an entirety of the suspension member 42 b. In other embodiments, the suspension member 42 b may only have two layers in certain areas, such as the areas of the pockets 90, 102. For example, the suspension member 42 b may not include the second layer 118 in locations within the suspension member 42 b that do not form the pockets 90, 102. That is, the suspension member 42 b may only include the second layer 118 at locations where the pockets 90, 102 are present. In the illustrated embodiment, the first layer 114 spans the entirety of the suspension member 42 b, and the second layer 118 is located only near the pockets 90, 102. In other embodiments, the second layer 118 may span the entirety of the suspension member 42 b, and the first layer 114 may be located only near the pockets 90, 102.
The suspension member 42 b includes one or more monofilaments 98 at the location of each of the pockets 90, 102. The monofilaments 98 may be inlaid in the knit structure of the suspension member 42 b, as described above. In the illustrated embodiment, the first layer 114 of the suspension member 42 b includes the monofilaments 98. In some embodiments, the second layer 118 may not include monofilaments 98 at the locations of the pockets 90, 102. In other embodiments, the second layer 114 may include the monofilaments 98 at the locations of the pockets 90, 102, and the first layer 114 may not include the monofilaments. In still other embodiments, both the first layer 114 and the second layer 118 may include the monofilaments 98 at the locations of the pockets 90, 102.
In the illustrated embodiment, the second layer 118 is sewn to the first layer 114 of the suspension member 42 b to form the pockets 90, 102 in the suspension member 42 b. Specifically, the second layer 118 is separately formed and then attached to the first layer 114. In some embodiments, the second layer 118 may be formed simultaneously (i.e., integrally) with the first layer 114 of the suspension member 42 b. For example, the suspension member 42 b may be formed through 3-D Flatbed knitting with two layers to form the pockets 90, 102. In such embodiments, the second layer 118 may be machine knit with the first layer 114 of the suspension member 42 b such that the pockets 90, 102 are integrally formed with the suspension member 42 b. In other embodiments, the second layer 118 may be attached to the first layer 114 using other suitable means (e.g., weaving, adhesives, staples, etc.). In any of the embodiments disclosed herein, the first and second layers 114, 118 may be formed of single jersey structure, a double jersey structure, a double jersey interlock structure, or another similar jersey knit structure.
FIGS. 7A and 7B illustrate the support pads 94, 122. The first support pad 94 is a thoracic support pad that provides support at the neck and between the shoulders of a user supported in the seating structure 10. The second support pad 122 is a lumbar support pad that provides support at the lower back of a user supported in the seating structure 10. In some embodiments, the thoracic support pad 94 and the lumbar support pad 122 may be inserted into the pockets 90, 102 during the manufacturing process such that the thoracic support pad 94 and the lumbar support pad 122 are not removable from the pockets 90, 102 once manufacturing is complete. In other embodiments, the pockets 94, 102 may be provided with slits or openings that enable a user to install and/or remove the thoracic support pad 94 and the lumbar support pad 122 from the pockets 90, 102 after manufacturing is complete. By positioning the support pads 94, 122 in the pockets 90, 102, the support pads 94, 122 are supported on backrest 18 without having to be connected to the frame 38 b, tilt mechanism 26, or other structure of the seating structure 10.
FIG. 7A illustrates the thoracic support pad 94. The thoracic support pad 94 includes an upper section 94 a and a lower section 94 b. In the illustrated embodiment, the upper section 94 a is wider than the lower section 94 b. FIG. 7B illustrates the lumbar support pad 122. The lumbar support pad 122 may be substantially similar to the thoracic support pad 94 of FIG. 7A. The lumbar support pad 122 also includes an upper section 122 a and a lower section 122 b. However, the upper section 122 a of the lumbar support pad 122 is thinner than the lower section 122 b of the lumbar support pad 122 in the illustrated embodiment. In some embodiments, the thoracic support pad 94, the lumbar support pad 122, or both supports 94, 122 may be shaped differently to cater to the individual needs of a user.
With continued reference to FIGS. 7A and 7B, the thoracic support pad 94 additionally incudes a thoracic connecting bar 126 that connects the upper section 94 a and the lower section 94 b of the thoracic support pad 94. The lumbar support pad 122 additionally includes a lumbar connecting bar 130 that connects the upper section 122 a and the lower section 122 b of the lumbar support pad 122. In the illustrated embodiment, the thoracic connecting bar 126 and the lumbar connecting bar 130 are curved. When the thoracic support pad 94 is secured, or retained, in the upper pocket 90, the thoracic connecting bar 126 may enable flex and rotation of the thoracic support pad 94 within the upper pocket 90. When the lumbar support pad 122 is secured, or retained, in the lower pocket 102, the lumbar connecting bar 130 may enable flex and rotation of the lumbar support pad 122 within the lower pocket 102.
FIGS. 7A and 7B illustrate only one example of a thoracic support pad and a lumbar support pad. In other embodiments, the support pads may have other configurations. For example, the support pads may only have one section and no connecting bars. Alternatively, the support pads may have more than two sections and multiple connecting bars. Each support pad may also have a different shape and/or size, depending on a user's preferences and application. The support pads may also be completely redesigned to support other areas of a user's anatomy (e.g., hip, buttocks, shoulders, neck, etc.). Regardless of the configuration, the support pads are generally thin members that are more rigid than the suspension member. The support pads, however, have suitable thicknesses to alter a topography of the suspension member. For example, in some embodiments, each support pad may have a thickness of at least 1 inch. As such, the support pads deform or reshape areas of the suspension member when inserted into a pocket. The support pads may have planar, curved (e.g., concave, convex, etc.), undulated, or other shaped surfaces that face a user to provide a desired support effect.
FIG. 8 illustrates a schematic view of the frame 38 b and the suspension member 42 b for the backrest 18. The suspension member 42 b is configured to engage a user. The illustrated suspension member 42 b also has a three-dimensional topography relative to a straight reference line A1 that extends between opposing sides of the frame 38 b. With additional reference to FIGS. 9A and 9B, the frame 38 b may define the straight reference line A1 between the opposing sides of the frame 38 b through any given cross-section of the frame 38 b. Specifically, the straight reference line A1 extends between a right side and a left side of the frame 38 b from the perspective of a user supported in the seating structure 10. Typically, a suspension member would extend straight across the frame 38 b directly along the straight reference line A1 at any given cross-section (depending on the shape of the frame 38 b). The illustrated suspension member 42 b, however, protrudes toward and/or away from the reference line A1 to create, or form, the three-dimensional topography relative to the straight reference line A1. Specifically, in the illustrated embodiment, the suspension member 42 b includes portions that extend toward the straight reference line A1 and portions that extends away from the straight reference line A1. Further, the illustrated suspension member 42 b includes at least one portion that extends across the straight reference line A1 at a location disposed within the frame 38 b. The at least one portion that extends across the straight reference line A1 is not located at the frame 38 b (i.e., not at the location of connection between the frame 38 b and the suspension member 42 b). In such an arrangement, a first section of the suspension member 42 b is positioned on a first side of the straight reference line A1 (e.g., a user-facing side of the straight reference line A1), and a second section of the suspension member 42 b is positioned on a second side of the straight reference line A1 (e.g., a rearward-facing side of the straight reference line A1). In some embodiments, the suspension member 42 b may extend across the straight reference line A1 at multiple points such that the multiple sections of the suspension member 42 b are positioned on each side of the straight reference line A1. In other embodiments, the suspension member 42 b may be positioned entirely on one side of the straight reference line (due to the shape of the frame 38 b), but the suspension member 42 b may still have a three-dimensional topography that extends toward and away from the suspension member 42 b independent of the frame 38 b.
The three-dimensional topography of the suspension member 42 b is formed independently of the frame 38 b. In other words, the three-dimensional topography is independent of the frame 38 b. For example, the portions of the suspension member 42 b that extend away from the straight reference line A1 and the portions of the suspension member 42 b that extend toward the straight reference line A1 do not depend on the shape of the frame 38 b. In prior art seating structures, the profile of a suspension member is defined solely by the shape of a frame or a structure attached to the frame (e.g., a lumbar support pad) that pushes against or pulls the suspension member. That is, the profile of a suspension member in prior art seating structures can only be varied by changing the shape of the frame. Even if the suspension member in the prior art seating structure does not extend directly along the straight reference line A1, the profile of the suspension member still follows the shape of the frame. In the illustrated embodiment, a profile of the suspension member 42 b (e.g., the portions extending toward and away from the straight reference line A1) may be created relative to both the frame 38 b and the straight reference line A1 without directly interacting with the frame.
In the illustrated embodiment, the three-dimensional topography of the suspension member 42 b includes protruding portions, one or more first recesses 138, and one or more second recesses 142. The protruding portions are formed, at least partially, by the thoracic support pad 94 and the lumbar support pad 122. When the thoracic support pad 94 is provided in the upper pocket 90 and the lumbar support pad 122 is provided in the lower pocket 102, the support pads 94, 122 result in a portion of the suspension member 42 b that protrudes from the straight reference line A1 toward a user supported in the seating structure 10. More specifically, the thoracic support pad 94 and the lumbar support pad 122 cause the first layer 114 of the pockets 90, 102 to protrude, or project, from the straight reference line A1 toward a user supported in the seating structure 10. In the illustrated embodiment, the support pads 94, 122 expand the respective pocket 90, 102 by at least one inch (e.g., in a front-to-rear direction). In other embodiments, the support pads 94, 122 may expand the respective pocket by a smaller or greater distance, depending on the thicknesses of the support pads 94, 122. The thoracic support pad 94 and the lumbar support pad 122 are supported by tensions within the suspension member 42 b, as will be described in more detail, and neither the thoracic support pad 94 nor the lumbar support pad 122 is directly connected to the frame 38 b. As such, the support pads 94, 122 create the protruding portions independently of the frame 38 b.
The first recesses 138 and the second recesses 142 are formed by how the first layer 114 is connected to the second layer 118. For example, with reference to FIGS. 5 and 6 , the second layer 118 may be connected to the first layer 144 at first stitchings 144 a and at second stitchings 144 b. In other embodiments, the second layer 118 may be connected to the first layer 114 in other ways (e.g., knits, adhesives, etc.) to form the recesses 138, 142. The first stitchings 144 a may form the first recesses 138, and the second stitchings 144 b may form the second recesses 142. Each of the first stitching 144 a and the second stitching 144 b applies tension to the first layer 114 that causes a corresponding portion of the first layer 114 of the suspension member 42 b to protrude, or project, from the straight reference line A1 away from a user supported in the seating structure 10. Neither of the stitchings 144 a, 144 b is directly connected to or engaged with the frame 38 b. Therefore, the stitchings 144 a, 144 b create the recess 138, 142 independently of the frame 38 b.
Each of the illustrated first recesses 138 extends linearly and adjacent to the upper pocket 90 along one side of the upper pocket 90. The first recesses 138 are configured to receive bone protuberances from a user supported in the seating structure 10. More specifically, the first recesses 138 receive the shoulder blades from a user supported in the seating structure 10. Each of the illustrated second recesses 142 along one side of the lower pocket 102. The second recesses 142 are also configured to receive bone protuberances from a user supported in the seating structure 10. More specifically, the second recesses 142 receive portions of a user's ilium supported in the seating structure 10. In other embodiments, the recesses 138, 142 may have other configurations. For example, the recesses 138, 142 may be non-linear (e.g., curved, wavy, zig-zagged, etc.). The suspension member 42 b may also include additional or alternative recesses located in other locations on the backrest 18.
Although the three-dimensional suspension member 42 b is described with reference to the backrest 18, similar features may also be applied to the suspension member 42 a of the seat 14. For example, the suspension member 42 a may include one or more recesses to provide relief for a user seated on the seat 14. In addition, the suspension member 42 may include one or more pockets that receive support pads to provide additional support in targeted areas for a user seated on the seat 14.
In the illustrated embodiment, providing the first layer 114 with monofilaments 98 enables a manufacturer to provide the suspension member 42 b with pre-tension to help create the three-dimensional topography without including additional frame members. With reference to FIGS. 8-9B, the first layer 114 is stretched across the frame 38 b of the backrest 18 and provides a first tension T1 for the suspension member 42 b. As such, the first layer 114 may also be referred to as a first tensile element that provides a first tensile force T1 in the suspension member 42 b. In the illustrated embodiment, the first tension T1 is at least partially directed toward a center of the backrest 18 and at least partially directed toward a user-supported side of the suspension member 42 b. The second layer 118 provides a second tension T2 for the backrest 18. As such, the second layer 118 may also be referred to as a second tensile element that provides a second tensile force T2 in the suspension member 42 b. In the illustrated embodiment with the second layer 118 provided at a central area of the backrest 18, the second tension T2 is at least partially directed toward the center of the backrest 18 and at least partially directed away from a user-supported side of the suspension member 42 b. The suspension member 42 b additionally has a third tension T3 directed toward a respective side of the frame 38 b in areas of the suspension member 42 b where the pockets 90, 102 are not located. The tensions T1, T2, T3 advantageously provide support for the support pads 94, 122 within the pockets 90, 102 such that the support pads 94, 122 are supported on the suspension member 42 b independent of the frame 38 b.
The tensions T1, T2, T3 are described herein with respect to a y-axis and an x-axis. In the illustrated embodiment, the y-axis extends toward and away from a user. With respect to the frame 38 b, the x-axis extends from a left side of the frame 38 b to a right side of the frame 38 b (and vice versa). In the illustrated embodiment, the first tension T1 includes a y component and an x component, and the second tension T2 includes a y component and an x component. In the illustrated embodiment, the y component of the first tension T1 and the y component of the second tension T2 are equal and extend opposite from one another along the y-axis. As such, the y components of the first tension T1 and the second tension T2 balance each other such that the suspension member 42 b is in equilibrium along the y-axis. In the illustrated embodiment, the x component of the first tension T1 and the x component of the second tension T2 extend the same way along the x-axis, but may be equal to each other or different than each other. The third tension T3 extends opposite from the x component of the first tension T1 and the x component of the second tension T2 along the x-axis and is equal to the sum of the x component of the first tension T1 and the second tension T2. As such, the third tension T3 and the x components of the first tension T1 and the second tension T2 balance each other such that the suspension member 42 is in equilibrium along the x-axis. The third tension T3 may also have a relatively small y component that balances the y components of the first tension T1 and the second tension T2. Therefore, the tensions T1, T2, T3 are provided such that the suspension member 42 b has negligible residual stresses and forces.
FIGS. 10A and 10B illustrate another embodiment of a suspension member 146 for the backrest 18 that forms the pockets 90, 102 of FIG. 4 . The suspension member 146 may be substantially similar to the suspension member 42 b of FIG. 4 except for the differences described below. The suspension member 146 includes a first layer 150, as illustrated in FIG. 10A, and a second layer 154, as illustrated in FIG. 10B. The first layer 150 includes a tunnel inlay of monofilaments 158. The second layer 154 includes two incision slits 162 that overlap opposing ends of the monofilaments 158 in the first layer 114. The incision slits 162 form a loop 164 in the second layer 154 of the suspension member 146. The loop 164 enables retention of the support pad 94 of FIG. 7A between the first layer 150 and the second layer 154 of the suspension member 146.
FIGS. 11A and 11B illustrate another embodiment of a suspension member 166 for the backrest 18 that forms the pockets 90, 102 of FIG. 4 . The suspension member 166 may be substantially similar to the suspension member 42 b of FIG. 4 except for the differences described below. The suspension member 166 includes a first layer 170, as illustrated in FIG. 11A, and a second layer 174, as illustrated in FIG. 11B. At the location of the pockets 90, 102, the first layer 170 includes outer portions 170 a and a central portion 170 b positioned between the outer portions 170 a, and the second layer 174 includes outer portions 174 a and a central portion 174 b positioned between the outer portions 174 a. In the first layer 170, the central portion 170 b includes a tunnel inlay of monofilaments 182 while the outer portions 170 a do not include monofilaments 182. In the second layer 174, the central portion 174 b does not include monofilaments 182 while the outer portions 174 a each include a tunnel inlay of monofilaments 182. The central portion 174 b of the second layer 174 includes a slit 186. The support pad 94 may be inserted into the slit 186 to position and retain the support pad 94 between the first layer 170 and the second layer 174 of the suspension member 166.
FIG. 12 illustrates another embodiment of a second layer 190 for the suspension member 42 b. For the sake of the brevity, the second layer 190 is described with reference to the suspension member 42 b of FIG. 4 , but the second layer 190 may be provided with any of the suspension members 42 b, 146, 166 described herein. The second layer 190 may be substantially similar to the second layer 118 of FIG. 5 except for the differences described below. The second layer 190 includes first and second longitudinally extending slots 194 a, 194 b. The support pad 94 may be inserted through the first and second longitudinally extending slots 194 a, 194 b along an insertion direction A2. The insertion direction A2 is defined such that the support pad 94 may be inserted into the first longitudinally extending slot 194 a from an exterior side of the second layer 190 that faces away from the first layer 114 of the suspension member 42 b (FIG. 5 ). As the support pad 94 is inserted into the first longitudinally extending slot 194 a, the support pad 94 extends from the first slot 194 a to the second slot 194 b along an interior side of the second layer 190 that faces the first layer 114 of the suspension member 42 b (FIG. 5 ) such that the support pad 94 is retained between the first layer 114 (FIG. 5 ) and the second layer 190.
FIG. 13 illustrates another embodiment of a second layer 198 for the suspension member 42 b. For the sake of the brevity, the second layer 198 is described with reference to the suspension member 42 b of FIG. 5 , but the second layer 198 may be formed with or attached to the first layer 114 of any of the suspension members 42 b, 146, 166 described herein. The second layer 198 may be substantially similar to the second layer 118 of FIG. 5 except for the differences described below. The second layer 198 includes a rectangular window 202 and monofilaments 206 that extend across the window 202. When the second layer 198 is attached to first layer 114 of the suspension member 42 b, the support pad 94 may extend partially out of the window 202. The monofilaments 206 provide support for the support pad 94 and may inhibit the support pad 94 from moving out of the window 202.
Although the suspension member 42 b has been described with respect to multiple embodiments, the suspension members 42 b are not limited to the embodiments described herein. Further, each embodiment of the suspension members 42 b described herein may include any of the features described with respect to any of the other embodiments of the suspension members 42 b.
In each of the above example embodiments, the support pads are not directly connected to the frames of the corresponding chairs. Instead, the support pads are directly supported by the suspension members and are only indirectly connected to the frames through the suspension members. As such, the chairs do not need to include any additional arms, beams, struts, or other structures extending from the frames to support and locate the support pads against the suspension members, like in conventional task chairs. The support pads can, thereby, be positioned anywhere on a backrest or seat without depending on a nearby frame to support the support pads. Positioning the support pads in different locations allows the suspension members to exhibit different 3-D topographies relative to the frames, as described above, without requiring structures from the frames to push or pull the suspension members in different directions.
Various features and advantages of the invention are set forth in the following claims.

Claims

What is claimed is:

1. A seating structure comprising:

a frame defining an opening; and

a suspension member coupled to the frame and spanning over the opening, the suspension member configured to engage a user and having a three-dimensional topography independent of the frame and relative to a straight reference line that extends between opposing sides of the frame.

2. The seating structure of claim 1, wherein the three-dimensional topography includes a recess that projects away from the user engaging the suspension member.

3. The seating structure of claim 1, wherein the three-dimensional topography includes a protruding portion that projects toward the user engaging the suspension member.

4. The seating structure of claim 3, wherein a support pad is supported on the suspension member, and wherein the support pad forms the protruding portion.

5. The seating structure of claim 4, wherein the support pad is not directly connected to the frame.

6. The seating structure of claim 1, wherein the frame is part of a backrest.

7. The seating structure of claim 1, wherein the frame is part of a seat.

8. The seating structure of claim 1, wherein the suspension member includes a first layer and a second layer attached to the first layer such that a tension differential is created between the first layer and the second layer, and wherein the tension differential between the first layer and the second layer at least partially creates the three-dimensional topography.

9. The seating structure of claim 1, wherein the suspension member crosses the straight reference line.

10. A seating structure comprising:

a base;

a backrest supported by the base, the backrest including a frame defining an opening;

a suspension member coupled to the frame and spanning over the opening;

a pocket defined in the suspension member; and

a support pad received in the pocket.

11. The seating structure of claim 10, wherein the suspension member includes a first layer and a second layer, and wherein the pocket is formed between the first layer and the second layer.

12. The seating structure of claim 11, wherein the second layer is attached to the first layer such that a tension differential is created in the suspension member, and wherein the support pad is supported within the pocket by the tension differential between the first layer and the second layer.

13. The seating structure of claim 10, wherein the pocket is a first pocket and the support pad is a thoracic support pad received in the first pocket, the seating structure further comprising:

a second pocket defined in the suspension member and spaced apart from the first pocket; and

a lumbar support pad received in the second pocket.

14. The seating structure of claim 10, wherein the suspension member is a knit suspension member having at least one monofilament.

15. The seating structure of claim 10, wherein the support pad is not directly connected to the frame.

16. A seating structure comprising:

a frame defining an opening;

a suspension member coupled to the frame and spanning over the opening, the suspension member including a first tensile element that provides a first tensile force in the suspension member and a second tensile element that provides a second tensile force in the suspension member; and

a support pad supported on the suspension member between the first tensile element and the second tensile element.

17. The seating structure of claim 16, wherein the first tensile element is a first layer of the suspension member, wherein the second tensile element is a second layer of the suspension member, and wherein the first layer and the second layer are attached to each other.

18. The seating structure of claim 16, wherein the support pad is not directly attached to the frame.

19. The seating structure of claim 16, wherein the first tensile force is at least partially directed toward a user-supported side of the suspension member, and wherein the second tensile force is at least partially directed away from the user-supported side of the suspension member.

20. The seating structure of claim 19, wherein the first tensile force is greater than the second tensile force.