CN116784616A

CN116784616A - Seating arrangement with headrest assembly

Info

Publication number: CN116784616A
Application number: CN202310786212.6A
Authority: CN
Inventors: G·J·皮特森; 罗伯特·J·拜蒂; 布鲁斯·M·史密斯; J·A·科拉桑蒂; F·比德莱; T·D·克鲁比捷维茨
Original assignee: Steelcase Inc
Current assignee: Steelcase Inc
Priority date: 2015-02-06
Filing date: 2016-02-05
Publication date: 2023-09-22
Also published as: EP3253256A1; EP3253256A4; CN107205557A; WO2016127066A1; EP3253256B1

Abstract

A seating arrangement comprising: a seat assembly; a backrest assembly operatively coupled to the seat assembly; and a headrest assembly coupled to the backrest assembly. The headrest assembly includes: a support device pivotably coupled to the backrest assembly for pivotal movement about a first pivot axis; a headrest member pivotally coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis; and a slide device coupling the headrest member to the support device to allow vertical sliding adjustment of the headrest member relative to the support device along an arcuate path.

Description

Seating arrangement with headrest assembly

The patent application is a divisional application; the application date of the original application is 2016, 02 and 05, and the application number is 201680009104.6, and the invention is named as seat arrangement with a headrest assembly. The original application is an international application, the international application number is PCT/US2016/016797, the international application date is 2016, 02, 05, and the national stage date entering China is 2017, 08, 07.

Technical Field

Various embodiments relate to a seating arrangement, and more particularly to an office chair assembly incorporating a headrest assembly having a pair of separately pivotable pivot and vertical adjustment devices.

Disclosure of Invention

In one embodiment, a seating arrangement comprises: a seat assembly adapted to support a user; a backrest assembly operatively coupled to the seat assembly and adapted to support a user; and a headrest assembly coupled to the backrest assembly. The headrest assembly includes: a support device pivotably coupled to the backrest assembly for pivotal movement about a first pivot axis; a headrest member pivotally coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis; and a slide device coupling the headrest member to the support device to allow vertical sliding adjustment of the headrest member relative to the support device along an arcuate path.

In another embodiment, a headrest assembly is adapted to be coupled to a seating arrangement, the headrest assembly comprising: a support device configured to be pivotably coupled to the backrest assembly of the seating arrangement for pivotal movement about a first pivot axis; a headrest member pivotally coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis; and a slide device coupling the headrest member to the support device, and configured to allow vertical sliding adjustment of the headrest member relative to the support device along an arcuate path.

In yet another embodiment, a seating arrangement comprises: a seat assembly adapted to support a user; a backrest assembly operatively coupled to the seat assembly and adapted to support a user; and a headrest assembly coupled to the backrest assembly. The headrest assembly includes: a support device coupled to the backrest assembly; a headrest member having an arc-shaped rail portion; and a slide device slidably coupling the track portion of the headrest member to the support device such that sliding adjustment of the headrest member relative to the support device causes the headrest member to travel along an arcuate path relative to the support device.

In yet another embodiment, a headrest assembly is adapted to be coupled to a seating arrangement, the headrest assembly comprising: a support device configured to be operably coupled to a backrest assembly of a seating arrangement; a headrest member having an arc-shaped support portion; and a slide device slidably coupling the support portion of the headrest member to the support device such that sliding adjustment of the headrest member relative to the support portion causes the headrest member to travel along an arcuate path relative to the support device.

In another embodiment, a seating arrangement comprises: a seat assembly adapted to support a user; a backrest assembly operatively coupled to the seat assembly and adapted to support a user; and a headrest assembly coupled to the backrest assembly. The headrest assembly includes: a support device pivotably coupled to the backrest assembly for pivotal movement about a first pivot axis; a headrest member configured to support a user and pivotably coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis, wherein pivoting of the headrest member about the second pivot axis is permitted independently of pivoting of the support means about the first pivot axis; and coupling means operatively coupling the headrest member to the support means such that the headrest member is pivotable about a pivot region spaced from the first pivot axis and the second pivot axis.

In yet another embodiment, a headrest assembly is adapted to be coupled to a seating arrangement, the headrest assembly comprising: a support device configured to be pivotably coupled to the backrest assembly of the seating arrangement for pivotal movement about a first pivot axis; a headrest member pivotally coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis, wherein pivoting of the headrest member about the second pivot axis is permitted independently of pivoting of the support means about the first pivot axis; and a coupling device configured to operatively couple the headrest member to the support device such that the headrest member is pivotable about a pivot region spaced from the first pivot axis and the second pivot axis.

In yet another embodiment, a seating arrangement comprises: a seat assembly adapted to support a user; a backrest assembly operatively coupled to the seat assembly and adapted to support a user; and a headrest assembly coupled to the backrest assembly. The headrest assembly includes: a support device pivotably coupled to the back assembly for pivotal movement about a first pivot axis, wherein the support device is located substantially in front of the back assembly when the headrest assembly is in the first position and is located substantially behind the back assembly when the headrest assembly is in the second position; a headrest member including a support surface adapted to support a user and pivotally coupled to the support device for pivotal movement about a second pivot axis spaced from the first pivot axis, wherein the support surface faces generally forward when the headrest assembly is in the first position and generally rearward 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 slide coupling the headrest member to the support device to permit vertical adjustment of the headrest member relative to the support device, and wherein an upper edge of the headrest member is proximate to the support device when the headrest assembly is in the first position and a lower edge of the headrest member is proximate to the support device when the headrest assembly is in the second position.

Another embodiment comprises a seating arrangement comprising: a seat assembly adapted to support a user; a backrest assembly operatively 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 device operably coupling the headrest assembly to the backrest assembly such that the headrest member is vertically adjustable relative to the backrest assembly, wherein at least one of the headrest member and the support device comprises a first plurality of detents and a second plurality of detents, wherein a detent of the first plurality of detents deflects a detent of the second plurality of detents; and an engagement member that alternately engages the first plurality of locking pins and the second plurality of locking pins when the headrest is vertically adjusted.

A further embodiment comprises a headrest assembly device adapted to be coupled to a seating arrangement, the headrest assembly device comprising: a headrest member adapted to support a user; a support device configured to operably couple the headrest member to a backrest assembly of the seating arrangement such that the headrest member is vertically adjustable relative to the backrest assembly, wherein at least one of the headrest member and the support device comprises a first plurality of detents and a second plurality of detents, wherein a detent of the first plurality of detents deflects a detent of the second plurality of detents; and an engagement member that alternately engages the first plurality of locking pins and the second plurality of locking pins when the headrest is vertically adjusted.

Yet another embodiment comprises a seating arrangement comprising: a seat support structure including a seat support surface configured to support a user sitting thereon; a back support structure, the back support structure comprising: an upward extension adapted to move between an upright position and a reclined position, a control link coupled to a rear portion of the seat support structure, and a second end coupled to a rear portion of the back support structure; a back support surface generally facing forward and configured to support a back of a seated user and having a lower portion and an upper portion coupled to an upward extension of the back support; and a back link coupled to a lower portion of the back support surface and to the seat support structure, wherein the back link moves the back support surface forward relative to an upward extension of the back support structure when the back support structure is moved from the upright position to the reclined position. The seating arrangement further includes a headrest assembly coupled to the back support structure, the headrest assembly including: a support device pivotably coupled to the backrest assembly for pivotal movement about a first pivot axis; a headrest member pivotally coupled to the support means for pivotal movement about a second pivot axis spaced from the first pivot axis; and a slide device coupling the headrest member to the support device, thereby allowing vertical sliding adjustment of the headrest member relative to the back support structure.

The features and advantages of these and other various embodiments will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

Drawings

FIG. 1 is a front perspective view of an embodiment of a chair assembly;

FIG. 2 is a rear perspective view of the chair assembly;

FIG. 3 is a side view of the chair assembly showing the chair assembly in a lowered position and in phantom showing a raised position, and showing the seat assembly in a retracted position and in phantom showing a deployed position;

FIG. 4 is a side view of the chair assembly showing the chair assembly in an upright position and in a reclined position shown in phantom;

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 the 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 sleeve assembly and seat assembly;

FIG. 10 is a cross-sectional view of the sleeve assembly;

FIG. 11 is an exploded perspective view of an alternative embodiment of a seat assembly;

FIG. 11A is an exploded perspective view of another alternative embodiment of a seat assembly;

FIG. 12 is a top perspective view of an alternative embodiment of a seat assembly;

FIG. 13 is a bottom perspective view of an alternative embodiment of a seat assembly;

FIG. 14 is an exploded bottom perspective view of an alternative embodiment of a seat assembly;

FIG. 15 is a top perspective view of a second alternative embodiment of a seat assembly;

FIG. 16 is a cross-sectional view of a second alternative embodiment of the seat assembly taken along line XVI-XVI of FIG. 15;

FIG. 17 is a cross-sectional view of a second alternative embodiment of the seat assembly taken along line XVII-XVII of FIG. 15;

FIG. 18 is a front perspective view of the backrest assembly;

FIG. 19 is a side view of the backrest assembly;

FIG. 20A is an exploded front perspective view of the backrest assembly;

FIG. 20B is an exploded rear perspective view of the backrest assembly;

FIG. 21 is an enlarged perspective view of region XXI of FIG. 20A;

FIG. 22 is an enlarged perspective view of region XXII in FIG. 2;

FIG. 23 is a cross-sectional view of the upper back pivot assembly taken along line XXIII-XXIII of 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 region XXV of FIG. 20B;

FIG. 26A is an enlarged perspective view of a comfort member and a lumbar support assembly;

FIG. 26B is a rear perspective view of the comfort member and 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 perspective view, partially in section, taken along line XXVIII-XXVIII of FIG. 26B;

FIG. 29A is a perspective view of the backrest assembly with a portion of the comfort member cut away;

FIG. 29B is an enlarged perspective view of a portion of the backrest assembly;

figure 30 is a perspective view of an alternative embodiment of a lumbar support assembly;

FIG. 31 is a cross-sectional view of the backrest assembly and an exterior trim assembly;

FIGS. 32A-32D are a partial assembly view of a back assembly and an exterior trim assembly;

FIG. 33 is an enlarged perspective view of region XXXIII of FIG. 32A;

34A-34H are a series of rear elevation views of sequential steps of a tie column and a pull cord secured thereto;

FIGS. 35A and 35B are alternative sequential steps of securing a drawstring to a tie column;

FIG. 36 is an exploded view of an alternative embodiment of a backrest assembly;

FIG. 37 is a cross-sectional side view of a top portion of an alternative embodiment of the backrest assembly;

FIG. 38 is a cross-sectional side view of a side portion of an alternative embodiment of a backrest assembly;

FIG. 39 is a front elevational view of the retaining member;

FIG. 40 is a front elevational view of the retaining member in a flipped inside out orientation;

FIG. 41 is a partial front elevational view of the retaining member stitched to the sleeve member;

FIG. 42 is a perspective view of the control input assembly supporting the 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 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 view of the chair assembly showing the plurality of pivot points thereof;

FIG. 48 is a side perspective view of the control assembly showing a plurality of pivot points associated therewith;

FIG. 49 is a cross-sectional view of the chair showing the backrest in an upright position with lumbar adjustment set to a neutral setting;

FIG. 50 is a cross-sectional view of the chair showing the backrest in an upright position with the lumbar portion set 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 the 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 portion set to a maximum arc;

FIG. 53 is an exploded view of a moment arm shift assembly;

FIG. 54 is a cross-sectional perspective view of the moment arm shift assembly along the LIV-LIV line of FIG. 43;

FIG. 55 is a top plan view of a plurality of control links;

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 the low tension position and the chair assembly in the upright position;

FIG. 57B is a side perspective view of the control assembly with the moment arm shift in the low tension position and the chair assembly in the reclined position;

FIG. 58A is a side perspective view of the control assembly with the moment arm shift in the high tension position and the chair assembly in the upright position;

FIG. 58B is a side perspective view of the control assembly with the moment arm shift in the high tension position and the chair assembly in the reclined position;

FIG. 59 is a graph of torque versus lean back at 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 view of the vertical height control assembly;

FIG. 65 is a cross-sectional perspective view of the first input control assembly taken along line LXV-LXV of FIG. 42;

FIG. 66A is an exploded perspective view of the control input assembly;

FIG. 66B is an enlarged perspective view of the clutch member of the first control input assembly;

FIG. 66C is an exploded perspective view of the control input assembly;

FIG. 67 is a cross-sectional side view of the variable back control assembly taken along line LXVII-LXVII of FIG. 42;

FIG. 68 is a perspective view of an alternative embodiment of a chair assembly including 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 a headrest assembly;

FIG. 71 is an exploded view of the components of an alternative embodiment of the back shell;

FIG. 72 is a cross-sectional view of the headrest assembly taken along line LXII-LXII of FIG. 69;

FIG. 73 is a rear perspective view of the fabric member after being joined to a subframe member 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 the sleeve removed;

FIG. 77 is a rear perspective view of the headrest assembly with the sleeve member and guide removed;

78A-78K are side views of the headrest assembly in various configurations and orientations;

FIG. 79 is a perspective view of another embodiment of a chair assembly;

FIG. 80 is a front elevational view of an embodiment of the chair assembly of FIG. 79;

FIG. 81 is a first side view of an embodiment of the chair assembly of FIG. 79;

FIG. 82 is a second side view of an embodiment of the chair assembly of FIG. 79;

figure 83 is a rear side view of an embodiment of the chair assembly of figure 79;

FIG. 84 is a top plan view of an embodiment of the chair assembly of FIG. 79;

FIG. 85 is a bottom plan view of an embodiment of the chair assembly of FIG. 79;

figure 86 is a perspective view of another embodiment of a chair assembly;

FIG. 87 is a front elevational view of an embodiment of the chair assembly of FIG. 86;

FIG. 88 is a first side view of an embodiment of the chair assembly of FIG. 86;

FIG. 89 is a second side view of an embodiment of the chair assembly of FIG. 86;

FIG. 90 is a rear side view of an embodiment of the chair assembly of FIG. 86;

FIG. 91 is a top plan view of an embodiment of the chair assembly of FIG. 86; while

Figure 92 is a bottom plan view of an embodiment of the chair assembly of figure 86.

Detailed Description

For purposes of the description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the embodiment 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. Thus, 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 each other, including elements that are directly or indirectly coupled to each other. In addition, the term "chair" as used herein encompasses various seating arrangements such as office chairs, car seats, home seats, stadium seats, theatre seats, and the like.

Reference numeral 10 (fig. 1 and 2) generally designates an embodiment of a chair assembly. In the illustrated example, the chair assembly 10 includes a castor base assembly 12 that abuts a supported floor surface 13, a control or support assembly 14 supported by the castor base assembly 12, a seat assembly 16 and a backrest assembly 18 each operatively coupled with the control assembly 14, and a pair of arm assemblies 20. The control assembly 14 (fig. 3) is operatively coupled to the base assembly 12 such that the seat assembly 16, the backrest assembly 18, and the arm assembly 20 are vertically adjustable between a fully lowered position a and a fully raised position B and are pivoted about a vertical axis 21 in a direction 22. The seat assembly 16 is operatively coupled with the control assembly 14 such that the seat assembly 16 is longitudinally adjustable relative 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 backrest assembly 18 are operatively coupled to the control assembly 14 and to each other such that the backrest 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, which correspond to the fully upright position E and the fully reclined position F of the backrest assembly 18, respectively.

The base assembly 12 includes a plurality of pedestal arms 24 extending radially and spaced apart from one another about a hollow central post 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. While the base assembly 12 is shown as including a multi-arm pedestal assembly, it is noted herein that other suitable support structures may be employed, including but not limited to stationary posts, multi-foot arrangements, vehicle seat support assemblies, stadium seating arrangements, home seating arrangements, theatre seating arrangements, and the like.

The seat assembly 16 (fig. 5A) includes a relatively rigid seat support plate 32 having a front edge 34, a rear edge 36, and a pair of C-shaped rails 38 defining side edges (fig. 5B) of the seat support plate 32 and extending between the front edge 34 and the rear edge 36. The seat assembly 16 also includes a pliable resilient seat shell 40 having a pair of upturned side portions 42 and an upturned rear portion 44 which cooperate to form an upwardly disposed generally concave shape, and a front edge 45. In the illustrated example, the seat shell 40 is constructed of a relatively pliable material such as a thermoplastic elastomer (TPE). In assembly, the seat shell 40 is secured and sandwiched between the seat support plate 32 and a plastic, pliable, resilient seat pan 46 that is secured to the seat support plate 32 by a plurality of mechanical fasteners. The seat pan 46 includes a front edge 48, a rear edge 50, side edges 52 extending between the front and rear edges 48, 50, and top and bottom surfaces 54, 56 that cooperate to 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 trailing edge 50. The slots 58 cooperate therebetween to define a plurality of fingers 60, each finger 60 being individually pliable, resilient. The seat pan 46 also includes a plurality of laterally oriented elongated apertures 62 located adjacent the leading edge 48. The apertures 62 cooperate to increase the overall flexibility of the seat pan 46 in its area and, in particular, to permit a front portion 64 of the seat pan 46 to flex in a vertical direction 66 relative to a rear portion 68 of the seat pan 46, as discussed further below. The seat assembly 16 also includes a foam cushion member 70 having an upper surface 76 and resting on the top surface 54 of the seat pan 46 and being recessed within the seat shell 40. The seat assembly 16 also includes a fabric seat cover 72 having a leading edge 73, a trailing edge 75, and a pair of side edges 77 extending between the leading edge 73 and the trailing edge 75. A spring support assembly 78 (fig. 5A and 5B) is secured to the seat assembly 16 and is adapted to flexibly support the front portion 64 of the seat pan 46 for bending in the vertical direction 66. In the illustrated example, the spring support assembly 78 includes a support housing 80 containing foam and having side portions 82 defining an upwardly concave arcuate shape. The spring support assembly 78 also includes a relatively rigid attachment member 84 extending transversely between the side portions 82 of the support housing 80 and between the support housing 80 and the front portion 64 of the seat pan 46. A plurality of mechanical fasteners 86 secure the support housing 80 and the attachment members 84 to the front portion 64 of the seat pan 46. The spring support assembly 78 also 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 proximal end 94 secured to the seat support plate 32 such that the distal end 90 of each cantilever spring 88 can 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 respective cantilever spring 88. In operation, as a seated user rotates forward on the seat assembly 16 and applies a downward force to its front edge, the cantilever springs 88 cooperate to allow the front portion 64 of the seat pan 46, and more generally the entire front portion of the seat assembly 16, to flex in the vertical direction 66.

Reference numeral 16a (fig. 6) generally designates another embodiment of the seat assembly. The seat assembly 16a is similar to the previously described seat assembly 16, so similar parts appearing in fig. 5A and 6-10, respectively, are represented by the same, corresponding reference numerals, except for the fact that in the illustrated example there is a suffix "a" in the numerals of the latter. The seat assembly 16a includes a relatively rigid seat support plate 32a having a leading edge 34a, a trailing edge 36a, and a pair of C-shaped rails 38a defining side edges of the seat support plate 32a and extending between the leading edge 34a and the trailing edge 36 a. The seat assembly 16a also includes a pliable resilient seat shell 40a (fig. 6 and 7) having a pair of upturned side portions 42a each terminating in a side edge 43a, and a front edge 45a, and an upturned rear portion 44a terminating in a rear edge 47a and including a flap portion 49a, wherein the side portions 42a and the rear portion 44a cooperate to form a generally concave shape disposed three-dimensionally upwardly. The seat shell 40a is constructed of a relatively pliable material, such as a thermoplastic elastomer (TPE), and is molded as a single unitary piece. In assembly, as described in further detail below, the seat shell 40a is secured and sandwiched between the seat support plate 32a and a plastic, pliable, resilient seat pan 46a that is secured to the seat support plate 32a by a plurality of mechanical fasteners. The seat pan 46a includes a front edge 48a, a rear edge 50a, side edges 52a extending between the front edge 48a and the rear edge 50a, and top and bottom surfaces 54a, 56a that mate into 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 rear edge 50 a. The slots 58a cooperate therebetween to define a plurality of fingers 60a, each finger 60a being individually pliable, resilient. The seat pan 46a also includes a plurality of laterally oriented elongated apertures 62a located adjacent the leading edge 48 a. The apertures 62a cooperate to increase the overall flexibility of the seat pan 46a in its area and, in particular, to permit a forward portion 64a of the seat pan 46a to flex in a vertical direction 66a relative to a rearward portion 68a of the seat pan 46a, as discussed further below. The seat assembly 16a also includes a foam cushion member 70a having an upper surface 76a and resting on the top surface 54a of the seat pan 46a and being recessed within the seat shell 40 a. The seat assembly 16a also includes a fabric seat cover 72a having a leading edge 73a, a trailing 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 to the spring support assembly 78 previously described.

As best shown in fig. 7 and 8, the pliable elastic seat shell 40a and fabric seat cover 72a cooperate to form an outer trim 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 front edges 45a of the seat shell 40a and the front edges 73a of the seat cover 72a, and the rear edges 47a of the seat shell 40a and the rear edges 75a of the seat cover 72a are respectively attached to each other to form the cover 100a and define the interior space 102a therein.

The flap portion 49a of the seat shell 40a includes a pair of corner edges 104a that each extend along a corner 106a of the seat shell 40a between the rear portion 44a and the corresponding side portion 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 apart from one another along the corner edge 104a, each tab including an aperture 110a extending therethrough. The tab 108a of the corner edge 104a is spaced apart from a plurality of tabs 112a spaced apart from one another along the corner edge 114a of each side portion 42 a. Each tab 112a includes an aperture 116a extending therethrough. The seat shell 40a also includes a plurality of integrally molded coupling tabs 118a spaced apart from one another about the inner edge 121a of the seat shell 40a, each having a Z-shaped, cross-sectional configuration.

In assembly, the outer trim cover assembly 100a (fig. 9) is constructed from the seat shell 40a and the seat cover 72a as described above. The seat pan 46a, cushion member 70a and spring support assembly 78a are then disposed relative to one another, assembled with the outer sleeve assembly 100a by placing the flap 49a in the open position I, positioning the seat pan 46a, cushion member 70a and spring support assembly 78a within the interior space 102a, and then moving the flap 49a to the closed position J. The pair of quick connect fasteners 120a each include a plurality of snap couplings 122a spaced apart from one another along the length of an L-shaped body portion 124 a. When assembled, the snap-fit couplings 122a are extended through the apertures 110a, 116a of the tabs 108a, 112a and are snappingly received within the corresponding apertures 126a of the seat pan 46a, thereby securing the corner edges 104a, 114a to the seat pan 46a and securing the flap portion 49a in the closed position J.

Thereafter, in assembly, the coupling tabs 118a (fig. 10) are positioned in the corresponding apertures 130a of the seat pan 46a such that the sleeve assembly 100a is temporarily secured to the seat pan 46a, thereby allowing further manipulation of the sleeve seat assembly 16a during assembly while maintaining the sleeve assembly 100a in connection and alignment with the seat pan 46a. "temporarily secured" is defined herein as a securement that is not intended alone to maintain the sleeve assembly 100a secured to the seat pan 46a during normal use of the chair assembly throughout its normal useful life. The support plate 32a is then secured to the underside of the seat pan 46a by a plurality of screws 132a, thereby sandwiching the coupling tab 118a between the support plate 32a and the seat pan 46a and permanently securing the sleeve assembly 100a to the seat pan 46a. "permanently affixed" is defined herein as a type of fixation that is desired to maintain the sleeve assembly secured to the seat pan 46a during normal use of the chair assembly throughout its normal useful life.

Reference numeral 16b (fig. 11) generally designates another embodiment of the seat assembly. The seat assembly 16b is similar to the seat assembly 16 and/or the seat assembly 16a previously described, and so similar parts appearing in fig. 5A-10 and 11-17, respectively, are identified by the same, corresponding reference numerals, except for the suffix "b" in the numerals of the latter. In the illustrated example, the seat assembly 16b is similar in configuration and structure to the seat assembly 16 and the seat assembly 16a, with the most notable exception being an alternatively configured and constructed seat shell 40b and outer trim cover 100b.

The seat assembly 16b (fig. 11) includes a pliable resilient seat shell 40b having a pair of upwardly turned side portions 42b each terminating in a side edge 43b, a front edge 45b, and an upwardly turned rear portion 44b terminating in a rear edge 47b, wherein the side portions 42b and rear portion 44b cooperate to form a generally concave shape disposed three-dimensionally upwardly. The seat shell 40b is constructed of a relatively pliable material, such as a thermoplastic elastomer (TPE), and is molded as a single unitary piece. In assembly, as described in further detail below, the seat shell 40b is secured and sandwiched between the seat support plate 32b, a plastic, pliable resilient seat pan 46b and a plastic, substantially rigid outer cover 51b, each of which is secured to the seat support plate 32b by a plurality of mechanical fasteners. The outer cover 51b has an upwardly arcuate shape and includes a rear wall 53b and a pair of forwardly extending side walls 55b, each of which includes a forward-most edge 57b, and wherein the rear wall 53b and side walls 55b cooperate to form an uppermost edge 59b. The seat pan 46b includes a front edge 48b, a rear edge 50b, side edges 52b extending between the front and rear edges 48b, 50b, and top and bottom surfaces 54b, 56b that mate in an upwardly disposed generally concave shape.

As best shown in fig. 12 and 13, the pliable elastomeric seat shell 40b, fabric seat cover 72b and outer cover 51b cooperate to form an outer trim 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 front edges 45b of the seat shell 40b and the front edges 73b of the seat cover 72b, and the rear edges 47b of the seat shell 40b and the rear edges 75b of the seat cover 72b are attached to each other, respectively, such that the seat shell 40b and the fabric seat cover 72b cooperate with the outer cover 51b to form the cover 100b and define the interior space 102b therein. The seat shell 40b also includes a plurality of integrally molded coupling tabs 118b spaced apart from one another about the inner edge 121b of the seat shell 40b, each having a Z-shaped, cross-sectional configuration.

In assembly, the seat shell 40b and the seat cover 72b of the outer cover assembly 100b (fig. 9) are coupled to one another as described above. As best shown in fig. 15 and 16, the side portion 42b of the seat shell 40b is coupled to the fabric seat cover 72b to define a corner 79b therebetween. It is noted that the use of both the fabric material of the fabric seat cover 72b and the TPE of the seat shell 40b provides a clear, aesthetic angle β of 90 ° or less while providing a soft, resilient, deformable feel to the user. The seat pan 46b, cushion member 70b and spring support assembly 78b are then disposed relative to one another and positioned within the interior space 102b of the sleeve 100b. The shell 40b is then secured to the seat pan 46b in lateral displacement by a plurality of integral hook-shaped couplings 123b that are spaced from one another about the periphery of the shell 40b and engage downwardly extending trim portions 125b extending about the side and rear periphery of the seat pan 46b. The housing 40b (fig. 17) also includes a plurality of Z-shaped couplings 127b integral with the housing 40b that are received within corresponding apertures 129b of the seat pan 46b, thereby temporarily securing the housing 40b to the seat pan 46b in terms of vertical displacement.

Thereafter, in assembly, the outer cover 51b (fig. 17) includes a plurality of integrally formed L-shaped hooks 131b that are spaced apart from one another along the side wall 55b and slidably engage a corresponding plurality of angled couplings 133b integrally formed with the seat pan 46b. Specifically, the hooks 131b engage the coupling 133b when the cover 51b is slid forward relative to the seat pan 46b. The overlay 51b is then secured in place by a pair of screws 135b, wherein the screws extend through corresponding apertures 137b of the overlay 51b and are received in threads in corresponding sleeves 139b of the seat pan 46b, thereby trapping the coupling 127b within the apertures 129 b. The support plate 32b is then secured to the underside of the seat pan 46b by a plurality of screws 132b, thereby sandwiching a plurality of spaced apart coupling tabs 141b integral with the outer cover 51b between the support plate 32b and the seat pan 46b and permanently securing the sleeve assembly 100b to the seat pan 46b. It is noted that the terms "temporarily affixed" and "permanently affixed" are defined in the foregoing.

The back rest assembly 18 (fig. 18-20B) includes a back rest frame assembly 200 and a back support assembly 202 supported thereby. The back frame assembly 200 generally comprises 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 also includes a pliable 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 the lower portion 220, a forward facing surface 224 and a rearward facing surface 226, wherein the upper portion 218 has a width that is substantially greater than the width of the lower portion 220 and the lower portion 220 tapers downwardly to generally follow the rear elevational configuration of the frame assembly 200. A lower reinforcement member 228 (fig. 29A) is attached to the hook 230 of the lower portion 220 of the back shell 216. The stiffening member 228 includes a plurality of protrusions 232 that engage a plurality of stiffening ribs 250 of the back shell 216 to prevent side-to-side movement of the lower stiffening member 228 relative to the back shell 216, while the stiffening member 228 pivotally interconnects the back control link 236 and the lower portion 220 of the back shell 216 at a pivot point or axis 590, all as described below.

The back shell 216 also includes a plurality of integrally molded, forwardly and upwardly extending hooks 240 (fig. 21) spaced from one another about the periphery of the upper portion 218 of the back shell. The 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 therebetween. The slots 244 cooperate to provide additional flexibility to the back shell 216 in its position. A pair of transverse ribs 246 cooperate with vertically extending ribs 248 integrally formed with and disposed at about the transverse midpoint of the former. As the back assembly 18 is moved from the upright position E to the reclined position F as described below, the vertical ribs 248 act to link the transverse ribs 246 together and reduce vertical expansion therebetween as the back shell 216 is flexed at its center 242. The plurality of laterally spaced stiffening ribs 250 extend longitudinally along the vertical length of the back shell 216 between the lower portion 220 and the middle portion 242. It is noted that the depth of each rib 250 increases along each rib 250 from the intermediate portion 242 to the lower portion 220 such that the overall rigidity of the back shell 216 increases along the length of the rib 250.

The back shell 216 (fig. 20A and 20B) also includes a pair of rearwardly extending, integrally molded pivot bosses 252 that form part of an upper back pivot assembly 254. The back pivot assembly 254 (fig. 22-24B) includes a pivot boss 252 of the back shell 216, a pair of cover members 256 surrounding the respective pivot boss 252, rail members 258, and a mechanical fastening assembly 260. Each pivot boss 252 includes a pair of side walls 262 and a rearwardly concave seating surface 264 having a vertically elongated pivot slot 266 extending therethrough. Each cover member 256 is shaped to closely receive a corresponding pivot boss 252 and includes a plurality of side walls 268 corresponding to side walls 262, and a rearwardly concave bearing surface 270 including a vertically elongated pivot slot 272 extending therethrough and adapted to align with the slots 266 of the corresponding pivot boss 252. The rail member 258 includes a central portion 274 extending transversely along and abutting the top frame portion 204 of the back frame assembly 200, and a pair of arcuate bearing surfaces 276 at the ends thereof. Specifically, the central portion 274 includes a first portion 278 and a second portion 280, wherein the first portion 278 abuts the front surface of the top frame portion 204 and the second portion 280 abuts the top surface of the top frame portion 204. Each bearing surface 276 includes an aperture 282 extending therethrough that is aligned with a corresponding sleeve member 284 integral with the back frame assembly 200.

In assembly, the cover member 256 is positioned about the respective pivot bosses 252 of the back shell 216 and operatively positioned between the back shell 216 and the rail member 258 such that the bearing surface 270 is sandwiched between the seating surface 264 of the respective pivot boss 252 and a bearing surface 276. The mechanical fastening assemblies 260 each include a bolt 286 that secures the circular abutment surface 288 of the bearing washer 290 in sliding engagement with the inner surface 292 of the corresponding pivot boss 252 and in threaded engagement with the corresponding sleeve member 284 of the back shell 216. In operation, the upper back pivot assembly 254 allows the back support assembly 202 to pivot relative to the back frame assembly about a pivot axis 296 (fig. 18) in a direction 294 (fig. 19).

The back support assembly 202 (fig. 20A and 20B) also includes a pliable resilient comfort member 298 (fig. 26A and 26B) that is attached to the back shell 216 and slidably supports a lumbar assembly 300. The comfort member 298 includes an upper portion 302, a lower portion 304, a pair of side portions 306, a front surface 308, and a rear 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 shown in fig. 20B and 25, the comfort member 298 includes a plurality of box-shaped couplings 314 spaced apart from one another about the periphery of the upper portion 302 that extend rearwardly from the rear surface 310. Each box-shaped coupler 314 includes a pair of side walls 316 and a top wall 318 that cooperate to define an interior space 320. A bar 322 extends between the side walls 316 and is spaced from the rear surface 310. Upon 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 spaces 320 of each box-shaped coupler 314 until the hooks 240 engage the corresponding rods 322. It is noted that the front surface 224 of the back shell 216 and the rear surface 310 of the comfort member 298 are void or void free proximate the hooks 240 and box-shaped couplers 314, thereby providing a smooth front surface 308 and increasing the comfort of a seated user.

The comfort member 298 (fig. 26A and 26B) includes an integrally molded, longitudinally extending sleeve 324 extending rearwardly from the rear surface 310 and having a rectangular cross-sectional configuration. The lumbar assembly 300 includes a forwardly laterally concave and forwardly vertically convex pliable, resilient main body portion 326 and an integral support portion 328 extending upwardly from the main body portion 326. In the illustrated example, the body portion 326 is shaped such that the body portion vertically tapers along its height such that it generally follows the contour 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 relative to the remainder of the back support assembly 202 between a fully lowered position I and a fully raised position J. The pawl member 330 selectively engages a plurality of apertures 332 spaced apart from one another along the length of the support portion 328 to releasably secure the lumbar support assembly 300 in a selected vertical position between the fully lowered position I and the fully raised position J. Pawl member 330 (FIGS. 27A and 27B) includes a housing portion 334 having an engagement tab 336 at an end thereof and offset rearwardly from an outer surface 338 of housing portion 334. A flexibly resilient finger 340 is centrally disposed within the housing portion 334 and includes a rearwardly extending pawl 342.

When assembled, the pawl member 330 (fig. 28) is positioned within the aperture 344 in 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 front surface 308 of the comfort member 298 and such that the engagement tab 336 of the housing portion 334 abuts the rear 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 pawls 342 are selectively engageable with the apertures 332, thereby allowing the user to optimize the position of the lumbar assembly 300 relative to the integral back support assembly 202. Specifically, the main 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 surrounds and guides along the side edges 222 of the back shell 216 and the corresponding side edges 306 of the comfort member 298. Alternatively, a lumbar assembly 300c (fig. 30) is provided wherein the main body portion 326c and the support portion 328c are integrally formed and the handle 346c is formed separately from the main body portion 326c and attached thereto. In an alternative embodiment, each handle 346c includes a pair of blades 350c that are received in corresponding pockets 352c of the body portion 326 c. Each blade 350c includes a pair of snap tabs 354c spaced apart along its length that snappingly engage an edge of one of a plurality of apertures 356c in the body portion 326 c.

In operation, a user adjusts the relative vertical position of the lumbar assemblies 300, 300c relative to the back shell 216 by grasping one or both of the handle portions 346, 346c and sliding the handle assemblies 346, 346c in a vertical direction along the comfort member 298 and the back shell 216. Stop tabs 358 are integrally formed within distal end 360 and are offset therefrom to engage an end wall of sleeve 324 of comfort member 298, thereby limiting the vertical downward travel of support portion 328 of lumbar assembly 300 relative to sleeve 324 of comfort member 298.

The backrest assembly 202 (fig. 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 its vertical length to correspond to the overall shape and taper of the backrest shell 216 and comfort member 298.

The back support assembly 202 also includes an outer trim 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 sleeve assembly 400 comprises a fabric material and includes a front side 402 (fig. 32A) and a rear side 404 that are stitched together along their respective side edges to form a first pocket 406 having a first interior or interior space 408 that receives the comfort member 298 and cushion member 362 therein, and a flap portion 410 that is stitched to and cooperates with the rear side 404 to form a second pocket 412 having a second interior or interior space 413 (fig. 32D) that receives the lumbar support assembly 300 therein.

In assembly, a first pocket 406 (fig. 32A) is formed by attaching respective side edges of the front side 402 and the rear side 404 to each other (e.g., by stitching or other suitable method of material making up the sleeve assembly 400) and to define a first interior space 408. One edge of flap portion 410 is then secured to the lower end of back side 404. Thereafter, in the illustrated example, the combination of the back shell 216 and the cushion member 362 is inserted into the interior space 408 of the first pocket 406 via the aperture 415 of the rear side 404 (fig. 32B). The outer sleeve assembly 400 is stretched around the cushion member 362 and the comfort member 298 and secured to the comfort member 298 by a plurality of apertures 420 through which upwardly extending hook members 424 (fig. 33) are received. Alternatively, the sleeve assembly 400 may be configured such that the aperture 420 is positioned to simultaneously receive the T-shaped attachment member 422 therethrough. In the illustrated example, the attachment member 422 and the hook member 424 are integrally formed with the comfort member 298. Each attachment member 422 is provided with a T-shaped cross-section or tie-post configuration having a first portion 428 extending rearwardly at right angles from within a recess 429 of the rear surface 310 of the comfort member 298, and a pair of second portions 430 located at and extending outwardly from the distal end of the first portion 428 opposite each other. One of the second portions 430 cooperates with the first portion 428 to form an angled engagement surface 432. Recess 429 defines an edge 434 at its periphery.

The sleeve assembly 400 is further secured to the comfort member 298 by a pull cord 436, wherein the pull cord extends through a pull cord passage 438 of the sleeve assembly 400 and is secured to the attachment member 422. In particular, and as best shown in fig. 34A-34H, each free end of the drawstring 436 is secured to the associated attachment member 422 in a manner that does not tie a knot and does not use mechanical fasteners separate from the comfort member 298. When assembled, the draw cord 436 and draw cord channel 438 are guided around a plurality of guide hooks 439 (fig. 26B) that are disposed around and integrally formed with the periphery of the comfort member 298. The pull cord 436 is wrapped around the associated attachment member 422 such that tension of the pull cord 436 about the attachment member 422 forces the pull cord 436 against the engagement surface 432 that is curved toward the recess 429, thereby forcing a portion of the pull cord 436 into the recess 429 and into engagement with at least a portion of the edge 434 of the recess 429 to achieve increased frictional engagement between the pull cord 436 and the comfort member 298. Fig. 35A and 35B illustrate alternative paths that the drawstring 436 may follow around the attachment member 422 relative to the steps illustrated in fig. 34G and 34H, respectively.

The lumbar assembly 300 (fig. 32C) is then aligned with the assembly of the sleeve assembly 400, the cushion member 362, and the comfort member 298 such that the main body portion 326 of the lumbar assembly 300 is positioned adjacent the middle section 414 of the sleeve assembly 400 and the support portion 328 of the lumbar assembly 300 and the comfort member 298 are coupled as described above. Flap portion 410 (fig. 32D) is then folded over lumbar support assembly 300, 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 through which the hooks 424 pass to receive the hooks 424. Distal edge 442 may also be sewn to rear side 404 of sleeve assembly 400. In the illustrated example, the side edges 446 of the flap portion 410 are not attached to the remainder of the sleeve assembly 400 such that the side edges 446 cooperate with the remainder of the sleeve assembly 400 to form a plurality of slots 448 through which the handle portions 346 of the lumbar assembly 300 extend. The second pocket 412 is configured to allow the lumbar assembly 300 to be vertically adjustable therein. The assembly of the sleeve assembly 400, cushion member 362, comfort member 298, and lumbar assembly 300 is then attached to the back shell 216.

Reference numeral 18d (fig. 36) generally designates an alternative embodiment to the backrest assembly. The backrest assembly 18d is similar to the backrest assembly 18 previously described, so similar parts appearing in fig. 20A and 20B and 36-41 are represented by the same, corresponding reference numerals, respectively, 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 exterior trim cover assembly 400d. In the illustrated example, the back shell 216d includes a generally pliable outer peripheral portion 450d (fig. 37 and 38) and a significantly less pliable rear portion 452d to which the peripheral portion 450d is attached. The rear portion 452d includes a plurality of laterally extending, vertically spaced apart 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 that extends around the periphery of the back shell 216d. The rear portion 452d includes a plurality of ribs 460d that are spaced apart from one another about the opening 458d and that serve to secure the cover assembly 400d to the back shell 216d as described below.

The sleeve assembly 400d includes a fabric sleeve 462d and a retention feature 464d extending about a peripheral edge 466d of the fabric sleeve 462 d. The fabric sleeve 462d includes a front surface 468d and a back surface 470d and preferably comprises a material that is flexible in at least one of a longitudinal direction and a transverse direction. As best shown in fig. 39, the retaining member 464d is annular and includes a plurality of widened portions 472d each having a rectangular cross-sectional configuration that are spaced apart from a plurality of narrowed corner portions 474d each having a circular cross-sectional configuration. Each widened portion 472d includes a plurality of apertures 476d spaced apart along its length adapted to engage the ribs 460d of the back shell 216d as described below. The holding member 464d is constructed of a relatively pliable plastic such that the holding member 464d may be turned inside out as shown in fig. 40.

Upon assembly, the retaining member 464d is secured to the rear surface 470d of the sleeve 462d such that the sleeve 462d is rotationally fixed with the widened portion 472d and such that the sleeve 462d is not rotationally fixed with the narrowed corner portion 474d along a line tangential to the longitudinal axis of the narrowed corner portion 474 d. In this example, the retention member 464d (fig. 41) is sewn around the peripheral edge 466d of the sleeve 462d, with the sewn seam passing through the widened portion 472d and around the narrowed corner portion 474 d. The sleeve assembly 400d of the retention member 464d and the sleeve 462d is aligned with the back shell 216d and the peripheral edge 466d of the sleeve 462d surrounds the back shell 216d such that the interior of the retention member 464d is flipped out. The retaining member 464d is then inserted into the opening or slot 458d such that tension in the fabric sleeve 462d stretched around the back shell 216d maintains the retaining member 464d positively engaged within the slot 458 d. The ribs 460d of the back shell 216d engage the corresponding apertures 476d of the retention member 464d to further secure the retention member 464d within the slot 458 d. It is noted herein that the stitch attaching the cover 462d to the retaining member 464d allows the narrowed corner portion 474d of the retaining member 464d to freely rotate relative to the cover 462d, thereby reducing aesthetic anomalies, such as bunching or overstretching of the fabric pattern, adjacent the corners of the cover 462 d.

The seat assembly 16 and the backrest assembly 18 are operatively coupled to and controlled by the control assembly 14 (fig. 42) and the control input assembly 500. The control assembly 14 (fig. 43-45) includes a housing or base structure or ground structure 502 including 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 cooperating 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 planar configuration including a pair of forwardly extending arm portions 524 that each include a forwardly located pivot aperture 526 that is pivotally secured to the base structure 502 by a pivot shaft 528 for pivotal movement about the upper and forward pivot points 516. The seat support structure 522 further includes a rear portion 530 extending laterally between and cooperating with the arm portions 524 to form an interior space 532 within which the base structure 502 is received. The rear portion 530 includes a pair of downwardly 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 also includes a pair of bushing assemblies 538 that cooperate to define a pivot point 540.

The control assembly 14 also includes a back support structure 542 having a generally U-shaped planar configuration and including a pair of forwardly extending arm portions 544, each of which includes a pivot aperture 546 and is pivotally coupled to the base structure 502 by a pivot shaft 548 such that the back support structure 542 pivots about the pivot point 518 below and forward. The back support structure 542 includes a rear portion 550 that cooperates with the arm portion 544 to define an interior space 552 that receives the base structure 502 therein. The back support structure 542 further includes a pair of pivot apertures 554 disposed along a length thereof that cooperate to define a pivot point 556. It is noted herein that in some cases, 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 also 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 to pivot about pivot point 540, and a second end 564 pivotably coupled to the respective pivot apertures 554 of the back support structure 542 by a pair of pivot pins 566 to pivot about pivot point 556. In operation, as the chair assembly is moved to the reclined position, the control link 558 controls movement of the seat support structure 522 relative to the back support structure 542, and in particular, the recline rate thereof, as described below.

As best shown in fig. 46A and 46B, the bottom frame portion 206 of the back frame assembly 200 is configured to be connected to the back support structure 542 via a quick connect device 568. Each arm portion 544 of the back support structure 542 includes a mounting aperture 570 at a proximal end 572 thereof. In the illustrated example, the quick connect device 568 comprises a configuration of the bottom frame portion 206 of the back frame assembly 200 including a pair of forwardly extending coupler portions 574 that cooperate to define a channel 576 therebetween, the channel 576 receiving the proximal end 572 of the arm portion 544 and the rear portion 550 therein. Each coupler portion 574 includes a downwardly extending sleeve 578 that is aligned with and received in a corresponding aperture 570. Mechanical fasteners (e.g., screws 580) are then threaded into the threads of the sleeve 578, thereby allowing the back frame assembly 200 to be quickly connected to the control assembly 14.

As best shown in fig. 47, the base structure 502, the seat support structure 522, the back support structure 542, and the control link 558 cooperate to form a four-bar linkage assembly that supports the seat assembly 16, the back assembly 18, and the arm assembly 20 (fig. 1). For ease of reference, the associated pivot assemblies associated with the four-bar linkage assembly of 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 is referred to as a first pivot point 516; the pivot point 518 between the base structure 502 and the back support structure 542 at the lower and forward is referred to as a second pivot point 518; the pivot point 540 between the first end 560 of the control link 558 and the seat support structure 522 is referred to as a 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 is referred to as a fourth pivot point 556. Further, fig. 47 shows the components of the chair assembly 10 in a reclined position in phantom, wherein the reference numerals of the chair in the reclined position are designated with the letter' ".

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, with positions E and F shown in upper and lower representations in fig. 47 as upper and lower portions of the back assembly 18 reclined 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 such that the seat support structure 522 pivots about the first pivot point 516 when the back support structure 542 pivots about the second pivot point 518. Preferably, the seat support structure 522 is rotated about the first pivot point 516 at a rate of between about 1/3 and about 2/3 of the rate at which the back support structure 542 is rotated about the second pivot point 518, more preferably the seat support structure 522 is rotated about the first pivot point 516 at a rate of about half the rate at which the back support structure 542 is rotated about the second pivot point 518, and most preferably, the seat assembly 16 reclines from the fully upright position G to an angle β of about 9 ° to the fully reclined position H when the back assembly 18 reclines from the fully upright position E to an angle γ of about 18 ° to the fully reclined position F.

As best shown in fig. 47, the first pivot point 516 is located above and forward of the second pivot point 518 whenever the chair assembly 10 is in the fully upright position or the fully reclined position, because the base structure 502 remains stationary relative to the supported floor surface 13 when the seat assembly 10 is reclined. The third pivot point 540 remains behind the first pivot point 516 and below its relative vertical height throughout the recline motion of the chair assembly 10. It is further noted herein that the distance between the first pivot point 516 and the second pivot point 518 remains greater than the distance between the third pivot point 540 and the fourth pivot point 556 throughout the recline motion of the chair assembly 10. As best shown in fig. 48, a longitudinally extending central 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 they form an acute angle α when the chair assembly 10 is in the fully reclined position ^’ . It is noted that the central axis 582 of the control link 558 does not rotate beyond an alignment orthogonal to the seat support structure 522 as the chair assembly 10 is moved between its fully upright and fully reclined positions.

With further reference to fig. 49, the back control link 584 includes a front end 585 that is pivotally coupled or connected to the seat support structure 522 at a fifth pivot point 586. The rear 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 also be rigidly fixed to each other. In addition, the pivot point 590 may include a stop that limits rotation of the back control link 584 relative to the back shell 216 in the first and/or second rotational directions. For example, referring to fig. 49, the pivot point 590 may include a stop 592 that allows the lower portion 220 of the back shell 216 to rotate clockwise relative to the control link 584. If it tends to reduce the dimension D ₁ The above configuration allows the lumbar support to become flatter, as a rearward/horizontal force is applied to the lumbar support portion of the back shell 216. However, the stop 592 can be configured to prevent the lower portion 220 of the back shell 216 from rotating in a counter-clockwise direction relative to the control link 584 (fig. 49). This results in the linkage control 584 and the lower portion 220 of the back shell 216 rotating at the same angular rate when the user reclines in the chair by pushing against the upper portion of the back assembly 18.

A cam link 594 is also pivotally coupled or connected to the seat support structure 522 for rotation about a 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) to tend to increase the angle(fig. 49) rotatably biases the back control link 584 and the cam link 594. The torsion springs 600 create 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. Accordingly, the torsion springs 600 tend to increase the angle +.>The stop 592 on the seat support structure 522 limits the counterclockwise motion of the back control link 584Rotated to the position shown in fig. 49. This force may also bias the control link 584 in a counterclockwise direction into the stop 592.

As discussed above, the back shell 216 is pliable, particularly as compared 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 thus pivots with the back support structure 542. The force generated by the torsion spring 600 urges the lower portion 220 of the back shell 216 upward. As also discussed above, the slots 244 in the back shell structure 216 create additional flexibility in the lumbar support portion or region 242 of the back shell 216. The force generated by the torsion spring 600 also tends to cause the lumbar portion 242 of the back shell 2126 to flex forward such that the lumbar portion 242 has a greater curvature than the area adjacent the torsion spring 600.

As discussed above, the position of the lumbar assembly 300 is vertically adjustable. Vertical adjustment of the lumbar assembly 300 also adjusts the manner in which the back shell 216 flexes/bends during recline of the chair back 18. For example, when the lumbar assembly 300 is adjusted to a neutral or neutral position, the curvature of the lumbar portion 242 (fig. 49) of the back shell 216 is also neutral or neutral. If the vertical position of the lumbar support assembly 300 is adjusted, the angle(fig. 50) is reduced and the curvature of the lumbar portion 242 is reduced. This also results in an angle +_, as shown in FIG. 50>Becomes larger and the overall shape of the back shell 216 becomes relatively flat.

With further reference to fig. 51, if the height of the lumbar assembly 300 is set at an intermediate level (i.e., as in fig. 49) and a user leans back, the four-bar linkage defined by the links and structures 502, 522, 542, 558 and the pivot points 516, 518, 540, 556 will move from the configuration of fig. 49 to the configuration of fig. 51 (as described above). This in turn results in an increase in the distance between the pivot point 586 and the cam surface 598. This results in an angleIncreasing from about 49.5 ° (fig. 49) to about 59.9 ° (fig. 51). As the spring rotates toward the open position, a portion of the energy stored in the spring is transferred into the back shell 216, thereby causing the curvature of the lumbar portion 220 of the back shell 216 to become greater. As such, the back control link 584, cam link 594, and torsion spring 600 provide a greater arc to the lumbar portion 242 as the user reclines in the chair to reduce the arc of the user's back.

Further, as the chair is reclined 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 174 millimeters to 234 millimeters. When the backrest 18 is tilted from the position in fig. 49 to the position in fig. 51, the dimension D between the lumbar portion 242 of the backrest shell 216 and the backrest frame structure 200 ₁ And also increases. Thus, during recline, although distance D increases somewhat, dimension D ₁ The increase in dimension D is reduced because the lumbar portion 242 of the back shell 216 is displaced forward relative to the back frame 200.

Referring again to fig. 49, when the user 606 is seated in the upright position, the spine 604 of the seated user 606 tends to curve forward a first amount in the lumbar region 608. As the user 606 reclines 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 a bit about the hip joint 610 relative to the user's femur 612. The increase in dimension D and the increase in curvature of the lumbar portion 242 of the back shell 216 ensures that the user's hip joint 610 and femur 612 do not slide on the seat 16 while also accommodating the curvature of the lumbar region 608 of the user's spine 604.

As discussed above, fig. 50 illustrates the back 18 of the chair in an upright position, wherein the lumbar portion 242 of the back shell 216 is adjusted to a flat position. If the chair back 18 is reclined from the position of fig. 50 to the position of fig. 52, then both the back control link 584 and the cam link 594 rotate in a clockwise direction. However, the cam link 594 rotates at a slightly higher rate, angleThus from 31.4 ° to 35.9 °. Distance D changes from 202 mm to 265 mm and angle +.>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, then the angle93.6 deg., and the distance D is 202 mm.

Accordingly, the back shell 216 flexes when the chair back 18 is reclined. However, if the arc is initially adjusted to a higher level, the arc added by the lumbar portion 242 from the upright to reclined position is significantly greater. This is an arrangement made in consideration of the fact that: if the back is initially in a relatively flat condition when the user is sitting upright, then the curvature of the user's back does not increase as much as the user reclines. And (3) the weight is as follows: if the user's back is relatively straight in the upright position, the user's back remains relatively straight even when reclined, although the arc increases slightly from the upright position to the reclined position. Conversely, if the user's back is significantly curved in the upright position, the increase in curvature of the lumbar region will be higher when the user reclines than a user whose back is initially relatively flat.

A pair of spring assemblies 614 (fig. 43 and 44) bias the back assembly 18 (fig. 4) from the reclined position F to the upright position E. As best shown in fig. 45, each spring assembly 614 includes a cylindrical 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 coupling member 624, and a second coupling member 626. In the illustrated example, the first coupling 624 is secured to the first end 618 of the housing 616, while the second coupling 626 is secured to a rod member 628 that extends through the coil spring 622. A washer 630 is secured to the distal end of the rod member 628 and abuts one end of the coil spring 622, while the other end of the coil spring 622 abuts the second end 620 of the housing 616. The first coupling member 624 is pivotally secured to the back support structure 542 by a pivot pin 632 for pivotal movement about a pivot point 634, wherein the pivot pin 632 is received within the pivot aperture 636 of the back support structure 542, and the second coupling member 626 is pivotally coupled to a moment arm shift assembly 638 (fig. 53-55) by a shaft 640 for pivotal movement 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) in which the force applied by the biasing assembly 614 to the backrest assembly 18 is increased relative to the low tension setting.

As shown in fig. 53-56, the moment arm shift assembly 638 includes: an adjustment assembly 644; a moment arm shift linkage assembly 646 operatively coupling the control input assembly 500 to the adjustment assembly 644 and allowing an operator to move the biasing assembly 614 between the low and high tension settings; and an adjustment assist assembly 648 adapted to reduce the magnitude of the input force exerted on the control input assembly 500 required by a user to move the moment arm shift assembly 638 from a low tension setting to a high tension setting, as described below.

The adjustment assembly 644 includes a pivot pin 650 that includes a threaded aperture that 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 by the bearing assembly 660 for pivoting about a longitudinal axis. The pivot pin 650 is supported by the base structure 502 (fig. 44) through a link assembly 662, the link assembly 662 including: a pair of link arms 664, each link arm 664 having: a first end 666 pivotably coupled to the second coupling 626 by a pivot pin 632; and a second end 668 pivotally coupled to the base structure 502 by a pivot pin 670 pivotally received in a pivot aperture 672 of the base structure 502 to pivot about a pivot point 674; and an aperture 675 that receives a corresponding end of the pivot pin 650. The pivot pin 650 is pivotally coupled along its length with a link arm 664.

The moment arm shift linkage assembly 638 includes a first drive shaft 676 extending between the control input assembly 500 and a first helical gear assembly 678, and a second drive shaft 680 extending between and operably coupling the first helical gear assembly 678 and a second helical gear assembly 682, wherein the second helical gear assembly 682 is connected to the adjustment shaft 652. The first drive shaft 676 includes a first end 684 that is operatively coupled to the control input assembly 500 by a first universal joint assembly 686, while a second end 688 of the first drive shaft 676 is operatively coupled to the first helical 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 coupling portion 692 of the first universal joint assembly 686, and the second end 688 of the first drive shaft 676 includes a female coupling portion 694 of the second universal joint assembly 690. The first bevel gear assembly 678 includes a housing assembly 696 that houses a first bevel gear 698 and a second bevel gear 700 therein. As shown, the first bevel gear 698 includes a male coupling portion 702 integral with the second universal joint assembly 690. The first end 706 of the second drive shaft 680 is coupled to a first bevel gear assembly 678 through a third universal joint assembly 704. The first end 706 of the second drive shaft 680 includes a female coupling portion 708 of the third universal joint assembly 704. The second bevel gear 700 includes a male coupling portion 710 with which the third universal joint assembly 704 is integral. The 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 a second bevel gear assembly 682 through a fourth universal joint assembly 718. The fourth universal joint assembly 718 includes a housing assembly 720 that houses: a first helical gear 722 coupled to the coupler member 716 by a fourth gimbal assembly 718, and a second helical 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 that is integral with the first bevel gear 722.

When assembled, the adjustment assembly 644 (fig. 53 and 54) of the moment arm shift assembly 638 is operatively supported by the base structure 502, while the control input assembly 500 (fig. 42) is operatively supported by the control input assembly mounting portion 536 (fig. 44) of the seat support structure 522. As a result, the relative angle and distance 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 position H. The third and fourth universal joint assemblies 704, 718 and splines 714 cooperate with the arrangement of the coupler 716 to compensate for the relative changes in these angles and distances.

The moment arm shift assembly 638 (fig. 53 and 54) acts to adjust the biasing assembly 614 between the low tension and high tension settings (fig. 57A-58B). Specifically, FIG. 57A illustrates the biasing assembly 614 in the low tension setting and the chair assembly 10 in the upright position, FIG. 57B illustrates the biasing assembly in the low tension setting and the chair assembly 10 in the reclined position, FIG. 58A illustrates the biasing assembly 614 in the high tension setting and the chair assembly 10 in the upright position, and FIG. 58B illustrates the biasing assembly in the high tension setting and the chair assembly 10 in the reclined position. The distance 730 measured between the pivot point 642 and the second end 620 of the housing 616 of the spring assembly 614 is used as a reference for the amount of compression applied to the spring assembly 614 when the moment arm shift assembly 638 is placed in the low tension setting with the chair assembly 10 in the upright position. Distance 730' (fig. 58A) comparatively illustrates the incremental compressive force applied to spring assembly 614 when moment arm shift assembly 638 is in the high tension setting and chair assembly 10 is in the upright position. The user adjusts the amount of force exerted by the biasing assembly 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 drives rotation of the adjustment shaft 652 of the adjustment assembly 644 via the moment arm shift linkage assembly 646 with input to the control input assembly 500, thereby advancing the pivot shaft 650 along the length of the adjustment shaft 654, thereby varying the compressive force exerted on the spring assembly 614 during the period that the pivot shaft 650 is articulated relative to the base structure 502. The pivot shaft 650 travels within a slot 732 disposed within a side plate member 734 attached to the associated side wall 508 of the base structure 502. It is noted that the distance 730' when the moment arm shift assembly 638 is in the high tension setting and the chair assembly 10 is in the upright position 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 exerted on the spring assembly 614 is greater when the moment arm shift is in the high tension setting than when the moment arm shift is in the low tension setting. Similarly, distance 736' (fig. 58B) is greater than distance 736 (fig. 57B), resulting in an increase in the biasing force exerted by biasing assembly 614 and forcing back assembly 18 from the reclined position to the upright position. It is noted herein that the change in the biasing force applied by the biasing assembly 614 corresponds to a change in the biasing torque applied about the second pivot point 518, and in some configurations, the biasing torque may be changed without changing the length of the biasing assembly 614 or the biasing force.

Fig. 59 is a graph of the amount of torque applied about the second pivot point 518 as the back support structure 542 is moved between the reclined position and the upright position, which urges the back support structure 542 from the reclined position to the upright position. In the illustrated example, the biasing assembly 614 applies a torque of about 652 in-lbs about the second pivot point 518 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 about 933 in-lbs 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 about 43%. Similarly, when the back support structure 542 is in the upright position and the moment arm shift assembly 638 is in the high tension setting, the biasing assembly 614 applies a torsion force of about 1.47e+03 inch-pounds about the second pivot point 518, and when the back support structure 542 is in the reclined position and the moment arm shift assembly 638 is in the high tension setting, about 2.58e+03 inch-pounds, resulting in a change of about 75%. The amount of torque applied by the biasing assemblies 614 varies considerably between the low tension setting and the high tension setting provided by the moment arm shift assembly 638 as the back support structure 542 is moved between the upright and reclined positions, which allows the overall chair assembly 10 to provide proper forward back support for users of different heights and weights.

An adjustment assist assembly 648 (fig. 53 and 54) assists the operator in moving the moment arm shift assembly 638 from the high tension setting to the low tension setting. The adjustment aid assembly 648 includes a coil spring 738 secured to the front wall 504 of the base structure 502 with a mounting structure 740, and a catch member 742 extending about the shaft 632 secured with the link arm 664, and includes a catch portion 744 defining an aperture 746 that captures a free end 748 of the coil spring 738. The coil spring 738 exerts a force F in an upward vertical direction on the catch member 742 and the shaft 632, as well as on the shaft 632 attached to the link arm 664, thereby reducing the input force that 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 described above, the seat assembly 16 (fig. 3) is longitudinally movable relative to the control assembly 14 between the retracted position C and the deployed position D. As best shown in fig. 60 and 61, the 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 relative to the control assembly 14. In the illustrated example, the seat support plate 32 (fig. 42) includes a C-shaped rail 38 that wraps around and slidably engages a corresponding guide flange 1570 of the control panel 1572 of the control assembly 14. A pair of C-shaped, longitudinally extending connection rails 1574 are positioned within the respective rails 38 and are coupled to the seat support plate 32. A pair of C-shaped bushing members 1576 extend longitudinally within the connection rail 1574 and are positioned between the connection rail 1574 and the guide flange 1570. The drive assembly 1564 includes a rack member 1578 having a plurality of downwardly extending teeth 1580. The drive assembly 1564 also includes a rack guide 1582 having a C-shaped cross-sectional configuration that defines a channel 1584 that slidably receives a rack member 1578 therein. The rack guide 1582 includes a slot 1586 disposed along its length that matingly receives the bearing member 1588 therein, wherein the bearing member 1588, as shown in phantom, illustrates the assembled alignment between the bearing member 1588 and the slot 1586 of the rack guide 1582, and further wherein the bearing member, as shown in solid, illustrates the assembled alignment between the bearing member 1588 and the rack member 1578. Alternatively, the bearing member 1588 can be formed as an integral part of the rack guide 1582. The drive assembly 1564 also includes a drive shaft 1590 having a first end 1592 that is universally coupled with the control input assembly 500 and a second end 1594 having a plurality of radially spaced teeth 1596. In assembly, the seat support plate 32 is slidably coupled to the control plate 1572 as described above, with the rack member 1578 secured to the underside of the seat support plate 32 and the rack guide 1582 secured within an upwardly opening channel 1598 of the control plate 1572. In operation, an input force applied by a user to the control input assembly 500 is transmitted through the linkage assembly 1566 to the drive assembly 1564, 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 seat support plate 32 to slide relative to the rack guide 1582 and the control plate 1572.

With further reference to fig. 62-64, the chair assembly 10 includes a height adjustment assembly 1600 that permits vertical adjustment of the seat 16 and back 18 relative to the base assembly 12. The height adjustment assembly 1600 includes a pneumatic cylinder 28 vertically disposed in the center post 26 of the base assembly 12 in a known manner.

A bracket structure 1602 is secured to the housing or base structure 502, while an upper end portion 1604 of the pneumatic cylinder 28 is received in an opening 1606 of the base structure 502 in a known manner (fig. 64). Pneumatic cylinder 28 includes an adjustment valve 1608 that can be moved downward to release pneumatic cylinder 28 to provide height adjustment. The bell crank 1610 has an upwardly extending arm 1630 and a horizontally extending arm 1640 configured to engage the release valve 1608 of the pneumatic cylinder 28. A bell crank 1610 is rotatably mounted to the bracket 1602. A cable assembly 1612 operatively interconnects the bell crank 1610 and the 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 ball fitting 1618 that is rotatably received in a ball socket 1622 formed in the bracket 1602. A second ball fitting 1624 is connected to one end 1626 of the inner cable 1614. The second ball fitting 1624 is rotatably received in a second ball socket 1628 of an 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 is wrapped around the wheel 1620, and the end fitting 1634 is connected to the inner cable 1614. The tension spring 1636 is connected to the end fitting 1634 and the seating structure at 1638. Spring 1636 creates tension on inner cable 1614 in one direction, and when valve 1608 is released, cable 1614 also displaces in the same direction to rotate bell crank 1610. The spring 1636 does not generate sufficient force to actuate the valve 1608, but the spring 1636 generates sufficient force to bias the arm 1640 of the bell crank 1610 into contact with the valve 1608. In this way, the rattling or loosening due to tolerances of the components is eliminated. During operation, a user manually rotates the adjustment wheel 1620, thereby creating 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 pneumatic cylinder 28 biases valve 1608 upwardly, moving valve 1608 to a non-actuated position after adjustment wheel 1620 is released.

The control input assembly 500 (fig. 42 and 65-67) includes a first control input assembly 1700 and a second control input assembly 1702, each adapted to communicate input from a user to chair members and functions coupled thereto, the chair members and functions being housed within a housing assembly 1704. The control input assembly 500 includes an anti-backdrive assembly 1706, an overload clutch assembly 1708, and a knob 1710. An anti-backdrive mechanism or assembly 1706 that prevents the direct drive assembly 1562 (fig. 60 and 61) and the seat assembly 16 from being driven between the retracted and deployed positions C, D without input from the control assembly 1700. The anti-backdrive assembly 1706 is received in the interior 1712 of the housing assembly 1704 and includes an adapter 1714 that includes a male portion 1716 of a universal adapter coupled to a second end 1594 of a drive shaft 1590 (fig. 61) at one end and a spline connector 1717 at the other end. The cam member 1718 is coupled to the adapter 1714 by a clutch member 1720. Specifically, cam member 1718 includes a splined end 1722 that is coupled to rotate with knob 1710, and a cam end 1724 having an outer cam surface 1726. Clutch member 1720 (fig. 66B) includes a pair of inwardly disposed splines 1723 that slidably engage spline connector 1717 having cam surfaces 1730 that cam engage outer cam surfaces 1726 of cam member 1718 as described below. The clutch member 1720 has a conical clutch surface 1719 that is engagingly received by a locking ring 1732 that is rotationally locked relative to the housing assembly 1704 and includes a conical clutch surface 1721 that corresponds to the clutch surface 1719 of the clutch member 1720 and that cooperate to form a conical clutch. A coil spring 1734 biases clutch member 1720 in a direction to engage locking ring 1732.

In the absence of 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 "back drive" or adjusting the seat assembly 16 between the retracted and extended positions C, D by simply applying a rearward or forward force to the seat assembly 16 in the absence of input from the first control input assembly 1700. In operation, the operator actuates the direct drive assembly 1562 via the first control input assembly 1700 to move the seat assembly 16 between the retracted and deployed positions C, D. Specifically, the rotational force applied to 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 out of the engaged position, wherein the clutch member 1720 is disengaged from the locking ring 1732. Rotational force is then transferred from the cam member 1718 to the clutch member 1720 to the adapter 1714, which is coupled to the direct drive assembly 1562 via the linkage assembly 1566.

It is noted herein that the small tolerances in the first control input assembly 1700 allow the cam member 1718 to move slightly (or "slosh") in both the linear and rotational directions as the clutch member 1720 is moved between the engaged and disengaged positions. A rotary annular damper element 1736 comprising a thermoplastic elastomer (TPE) is located within an interior 1712 of the housing 1704 and is attached to the clutch member 1720. In the illustrated example, the damping element 1736 is forced 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 a lowered position a and a raised position B as described below.

The second control input assembly 1702 is adapted to adjust the tension applied to the backrest assembly 18 upon recline and to control the recline of the backrest assembly 18. The first knob 1740 is operably coupled to the moment arm shift assembly 638 by the moment arm shift linkage assembly 646. In particular, the second control input assembly 1702 includes a male coupling portion 1742 that couples with a female gimbaled coupling portion 692 (fig. 53 and 55) of the shaft 676 of the moment arm shift linkage assembly 646.

The second knob 1760 is adapted to adjust the rearward inclination of the back assembly 18 via a cable assembly 1762 that operably couples the second knob 1760 to the variable back stop assembly 1764 (fig. 67). The cable assembly 1762 includes a first cable guide structure 1766, a second cable guide structure 1768, and a cable tube 1770 extending therebetween that slidably receives an actuation cable 1772 therein. The cable 1772 includes a distal end 1774 that is fixed relative to the base structure 502 and biased in the direction of 1776 by a coil spring 1778. The variable back stop assembly 1764 includes a stop 1780 having a plurality of vertically stepped steps 1782, a support bracket 1784 fixedly supported relative to the seat assembly 16, and a slide member 1786 slidably coupled to the support bracket 1784 to slide in a fore-aft direction 1788 and fixedly coupled to the stop member 1780 by 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-aft direction 1788. In operation, the user adjusts the position of stop member 1780 by input to second knob 1760 to adjust the potential back tilt. As the back assembly 18 moves from the upright position to the reclined position, a selected one of the steps 1782 of the stop member 1780 contacts the rear edge 1792 of the base structure 502 to limit the available back recline.

Reference numeral 10e (fig. 68) generally designates another embodiment of a chair assembly or seating arrangement. Since the seating arrangement 10e is similar to the seating arrangement or chair assembly 10 described previously, parts similar to those appearing in FIGS. 1 and 2 and 68 are designated by the same corresponding reference numerals, except that the latter is numbered with the suffix "e". In the example shown, the seating arrangement 10e includes a headrest assembly 2000 pivotally coupled with a backrest assembly 18 e. The headrest assembly 2000 includes a support assembly 2002 and a headrest member 2004. As best shown in fig. 69 and 70A, the support assembly 2002 includes a support 2006 pivotally coupled to the backrest assembly 18e by a first hinge 2008. The support 2006 has a generally U-shaped configuration including a laterally extending base 2010 and a pair of upwardly extending arms 2012. Each arm includes a vertical portion 2014 and a terminal portion 2016, the terminal portion 2016 extending upwardly and slightly forwardly from the associated vertical portion 2014. The first hinge assembly 2008 includes a pair of hinges 2018 that allow the support 2006 to be pivotally coupled to the back assembly 18e to rotate in a direction 2022 about a laterally extending first pivot axis 2020. Each hinge 2018 comprises a friction locking hinge wherein the rotational position of the support 2006 relative to the back assembly 18e is maintained in place by friction within the hinge 2018. Specifically, the hinge 2018 couples the support 2006 to the upper portion 218e of the back shell 216e (fig. 71). In the example shown, the back shell 216e includes grooves 2021 and the comfort 298e includes grooves 2023, each for receiving the base 2010 therein. The support assembly 2002 further comprises a support cover 2025 for covering the front of the base portion 2010, while the rear cover 2027 covers the rear of the back shell 216 e. In adjustment, the frictional forces within the hinge 2018 are overcome by a sufficient force applied by the user to the headrest assembly 2000. After adjustment, the force applied by the user is released and friction in the hinge 2018 holds the support 2006 in the selected rotational position. Note that no external or independent releasable locking assembly holds or secures the support 2006 in a rotational position relative to the back assembly 18 e.

The support assembly 2000 further comprises a second hinge device 2024, the second hinge device 2024 comprising a guide 2026, the guide 2026 having a flat body 2028 and a pair of tubular ends 2030, each of the pair of tubular ends 2030 having an outwardly opening aperture 2032. The second hinge device 2024 further comprises a pair of friction locking hinge devices 2033 (fig. 72), the pair of friction locking hinge devices 2033 rotatably coupling the headrest member 2004 to the support 2006, rotating in a direction 2036 about a laterally extending second pivot axis 2034 (fig. 69). Each hinge 2033 (fig. 72) includes a hinge 2038, and the hinge 2038 includes: a first end 2040, the first end 2040 press-fitted into an associated aperture 2032 of one of the ends 2030 of the guide 2026 and fixed against rotation; and a second end 2042 press-fitted into the aperture 2044 of one of the distal end portions 2016 of the arm portions 2012 of the support 2006 and fixed to be non-rotatable. The hinge 2033 allows the headrest member 2004 to pivot about a second pivot axis 2034 relative to the support member 2006. As described above, each hinge 2033 includes a friction locking hinge in which the rotational position of the headrest member 2004 is held in place by friction within the hinge 2033. In adjustment, the frictional forces within the hinge 2033 are overcome by a sufficient force applied by the user to the headrest member 2004. After adjustment, the force applied by the user is released and friction within the hinge 2033 holds the headrest member 2004 in the selected rotational position. Note that no external or independent releasable locking assembly holds or secures the headrest member 2004 in a rotational position relative to the support member 2006. End cap 2046 is located within the end of aperture 2044. The dual pivot adjustment allowing the headrest member 2004 and the support member 2006 to pivot and reposition about the first pivot axis 2020 and the second pivot axis 2034 allows the headrest to be repositioned in a variety of positions and orientations relative to the backrest assembly 18e and a person seated within the seating arrangement 10e, as described further below. Alternatively, the headrest assembly may include a support having a single arm and/or a single hinge for coupling the support to the backrest assembly and/or a single hinge for coupling the headrest to the support.

The headrest member 2004 is also vertically adjustably supported by a support member 2006 for adjustment in a direction 2047. In the first embodiment, the headrest member 2004 (fig. 70A) includes: a frame member 2048; a subframe member 2050, the subframe member 2050 being releasably coupled to the frame member 2048; and a mesh cover 2052, the mesh cover 2052 being attached to the frame member 2048 by a subframe member 2050. Although mesh cover 2052 is included in this example, note that non-mesh and other materials may be used. The sleeve 2052 comprises: a forward-facing support surface 2054, the forward-facing support surface 2054 configured to support a head and/or neck of a seated user; and a rim 2056, the rim 2056 extending rearward from the support surface 2054. A pair of horizontal frame bars or attachment bars 2058 are positioned and secured along the top and bottom of the package rim 2056, while a pair of vertical frame bars or attachment bars 2059 are positioned and secured along the sides of the package rim 2056. In assembly, the wrapping edge 2056 (fig. 73) of the sleeve 2052 wraps around the outer periphery of the subframe member 2050, and the attachment strip 2058 is coupled to the rear surface of the subframe member 2050. As best shown in fig. 73-75, the horizontal attachment bars 2058 each have an arrow-like cross-sectional configuration including an enlarged head 2061, the enlarged head 2061 engaging a plurality of flat projections 2063 and a plurality of contoured projections 2065 spaced along the upper and lower edges of the subframe 2050, while the vertical attachment bars 2059 engage a plurality of flat projections 2065 spaced along the sides of the subframe 2058. Tension in the mesh enclosure 2052 maintains the vertical attachment strips 2059 in engagement with the plano-convex heads 2065 and may be maintained between the convex heads 2065 and the outer wall 2049. The subframe 2050 is then releasably snap-coupled to the frame member 2048 such that the rim 2056 and attachment strip 2058 are sandwiched and hidden between the subframe member 2050 and the frame member 2048.

In a second embodiment, the subframe 2050 and mesh fabric cover 2052 of the first embodiment shown in fig. 70A may be replaced by a decorative ring 2051 (fig. 70B), a foam piece 2053, and an outer fabric cover 2055. In assembly, the plurality of attachment strips 2057 secure the fabric sleeve 2055 to the decorative ring 2051 with the foam piece 2053 sandwiched between the sleeve 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 sleeve 2052 are sandwiched between the decorative ring 2051 and the frame 2048.

The frame member 2048 comprises: a peripheral extension frame portion 2060, to which the subframe piece 2050 is attached; and a vertically extending, forwardly convex, arcuate central portion 2062. The center portion 2062 (fig. 70) includes: a vertically extending elongated slot 2070; a first set of rearwardly facing, vertically spaced apart raised heads 2072; and a second set of rearwardly facing, vertically spaced apart tabs 2074, the second set of rearwardly facing, vertically spaced apart tabs 2074 being located on opposite sides of the slot 2070 relative to the first set of tabs 2072. Note that the projections of the first set of projections 2072 offset the projections of the second set of projections 2074 in the vertical direction. A pair of fastening portions 2078 at the ends thereof fix a pair of leaf springs 2076 to the planar portion 2028 of the guide 2026. Each spring 2076 also includes an engagement portion 2080, with the engagement portion 2080 being located between the fastening portions 2078 and biased toward the first set of prongs 2072 and the second set of prongs 2074. The attachment 2082 is attached to the guide 2026 by a pair of screws 2086 such that the central portion 2062 is slidably sandwiched between the guide 2026 and the attachment 2082, and the sliding motion is guided by shims 2085 positioned with slots 2070. The sleeve 2083 snaps over and encapsulates the back of the central portion 2062.

In the adjustment, the user adjusts the headrest member 2004 relative 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 a vertical direction 2047 and pivoting the headrest member 2004 about a pivot region 2079 spaced from the headrest member 2004 and the support assembly 2002. The headrest member 2004 is maintained in a selected vertical position by engaging the engagement portion 2080 of one of the leaf springs 2028 with an associated set of raised heads 2072, 2074. As described above, the projections in the first set of projections 2072 and the second set of projections 2074 are offset from each other in the vertical direction such that only one set of projections is engaged by the spring 2076, thereby improving the effective vertical adjustability of the headrest member 2004. Alternatively, incremental offset adjustability of the headrest member 2004 as provided by the vertically offset tabs 2072, 2074 may be provided by offsetting the springs 2076 from one another in the vertical direction when the tabs 2072, 2074 are aligned with one another. In another embodiment, the prongs 2072, 2074 may be offset from each other in the vertical direction and the springs 2076 may be offset from each other in the vertical direction.

The dual pivotal and vertical adjustability of the headrest assembly 2000 allows the headrest assembly 2000 to be positioned between a wide variety of points and assume a number of configurations to accommodate a wide variety of different users in the manner shown in fig. 78A-78K. For example, the headrest assembly 2000 may be adjusted between a forward position, such as shown in fig. 78I, in which the support assembly 2002 is rotated to a forward position relative to the backrest assembly 18e, and in a vertical direction, the headrest member 2004 is adjusted to a lowered position relative to the support assembly 2002, and a rearward position, such as shown in fig. 78J, in which the headrest member 2004 is adjusted to a most elevated position relative to the support assembly 2002, and the support assembly 2002 is rotated to a rearward position relative to the backrest assembly 18 e. In these and other embodiments, the headrest member 2004 may rotate about the support assembly 2002 such that it makes physical contact with either the support assembly 2002 or the backrest assembly 18 e. For example, in the position shown in fig. 78I, the lower edge (e.g., positioned) of the headrest member 2004 may be brought into contact with the front surface of the backrest assembly 18e, while in the position shown in fig. 78K, the lower edge (e.g., positioned) of the headrest assembly 2004 may be brought into contact with the rear surface of the backrest assembly 18e or the support assembly 2002.

In some embodiments, one or more stops may be disposed within 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 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 the selected position.

In the foregoing description, it will be readily appreciated by those skilled in the art that various alternative combinations of the components and elements of the invention, various modifications of the invention, as applicable to vehicle seats, stadium seats, home seats, theatre seats and the like, may be made without departing from the disclosed concepts. Such modifications are to be considered as included in the following claims unless these claims, by their language, expressly state otherwise.

Claims

1. A chair having a headrest member positioned on top of a backrest of the chair, comprising:

a support having a top end and a bottom end;

the top end being pivotally and slidably connected to the back of the headrest member such that the headrest member is capable of sliding vertically over the top end;

Wherein the bottom end is pivotally connected to the top of the backrest of the chair such that the support can swing about the pivot towards the back of the chair to avoid a user sitting in the chair leaning thereon.

2. The chair of claim 1 wherein the back of the headrest is arcuate about a horizontal axis.

3. The chair of claim 1 wherein the support is configured to swing 180 degrees about the pivot axis between the chair back and the chair front.

4. The chair of claim 1, wherein the headrest member moves in a front-rear direction when the headrest member slides vertically with respect to the top end of the support member.

5. The chair of claim 1 wherein the top end of the support pivots about a first axis and the bottom end pivots about a second axis, and wherein the headrest is movable between a first position in which the pivot between the top end of the support and the headrest is forward of the pivot between the bottom end of the support and the back of the chair, and a second position in which the pivot between the top end of the support and the headrest is rearward of the pivot between the bottom end of the support and the back of the chair.

6. The chair of claim 1 wherein the slidable connection between the top end of the support member and the headrest member is configured such that when the headrest member slides relative to the support member, the headrest member pivots about a pivot region spaced from at least one of the headrest member and the support member.

7. The chair of claim 6 wherein the slidable connection between the top end of the support member and the headrest member is configured such that when the headrest member slides relative to the support member, the headrest member pivots about a pivot region spaced apart from the headrest member and the support member.

8. The chair of claim 1 wherein the distance between the pivot axis between the top end of the support and the headrest and the pivot axis between the bottom end of the support and the backrest remains substantially constant as the headrest is vertically adjusted relative to the backrest.

9. The chair of claim 1 wherein the bottom end of the support is pivotably coupled to the backrest by a first friction hinge.

10. The chair of claim 9, wherein the headrest member is pivotably coupled to the top end of the support member by a second friction hinge.

11. The chair of claim 1, further comprising:

a spring-biased engagement member that frictionally engages the headrest member such that the headrest member is selectively adjustable between a plurality of vertical positions relative to the backrest.

12. The chair of claim 11 wherein the headrest member includes a plurality of detents spaced apart from one another and selectively engageable by the spring biased engagement member to retain the headrest member in the upright position.

13. The chair of claim 12, wherein the plurality of locking pins is one of a pair of plurality of locking pins comprising a first plurality of locking pins and a second plurality of locking pins, the locking pins of the first plurality of locking pins being offset from the locking pins of the second plurality of locking pins such that the engagement members alternately engage the first plurality of locking pins and the second plurality of locking pins when the headrest member is vertically adjusted.

14. The chair of claim 1 wherein the headrest member has a forwardly projecting arcuate support surface.

15. The chair of claim 1 wherein sliding the headrest member relative to the support member causes the headrest member to travel along an arcuate path relative to the support member.

16. The chair of claim 1 wherein the headrest member is pivotable relative to the support member independently of the pivoting of the support member relative to the backrest.