The present invention relates to office-type seating, and more particularly to a knit seat back for office-type seating.
Conventional office-type chairs generally include a base, a pedestal or cylinder that extends upwardly from the base, a seat mounted on the base for supporting the user, and a chair back extending upwardly from the seat to provide a back support for the user. In most cases, the back support is capable of tilting or reclining with respect to the seat.
Modern office seat back supports commonly fall into two categories. In a first category, the back support has a central frame that extends upwardly from the seat. A fabric cover is fitted and attached over the central frame, and the fabric cover provides an aesthetically pleasing and comfortable surface for the user. In a second more recently developed category, the seat back includes a peripheral frame extending upwardly from the seat, and the peripheral frame forms a central opening. A fabric, often referred to as a suspended mesh, is held in tension over the central opening. The tension of the fabric provides a degree of flexibility and cushioning for the user and also forms the outer, user engaging surface.
In an attempt to simplify manufacturing processes and increase the aesthetic appearance of fabric covers for both seat back styles, manufacturers have turned to knit fabrics. Knitting may be generally classified as either weft knitting or warp knitting. In both weft knitting and warp knitting, one or more yarns are manipulated to form a plurality of intermeshed loops that define a variety of courses and wales. In weft knitting, the courses and wales are perpendicular to each other and may be formed from a single yarn or many yarns. In warp, knitting, however, the wales and courses run roughly parallel and one yarn is required for every wale.
The weft-knitting technique is often desirable because it allows manufacturing of fabric materials in predetermined, variable patterns, the yarn or the needle size being selected accordingly. Modern knitting machines enable a manufacturer to program the locations of various types of loops with multiple yarns across a one-piece knit material, resulting in a desired overall appearance with desired yarns positioned in predetermined locations on the final knit piece (such as a seat back). In some cases, multilayer knits are utilized, wherein an inlay yarn, which may be of a different material than the weft yarns, is placed in between the front and rear layers of the knit in one or more areas. Sometimes referred to as a “lofted” knit, the inlay yarn can have structural capabilities that provide a depth between the weft layers and create a degree of cushioning within the knit fabric.
The present invention provides a seat back for an office chair that includes a knit material for extending over a structural frame. The knit material can be formed in a single knitting operation to include cushioning characteristics that vary across different regions of the knit material.
In one embodiment, the seat back includes a back frame and a weft knit material attached to the back frame. The weft knit material and back frame together form a back support for a user. The knit material has a first layer formed from a first material, a second layer formed of a second material, and a third layer formed of a third material, wherein the third layer is inlayed between the first and second layers and the third material is different from at least the first and second materials. The first and second layers are knit according to a predetermined pattern, the predetermined pattern determining crossing lines where the first and second layers cross one another and fix the third layer in position with respect to the first and second layers. The predetermined pattern is differentiated between regions of the back support, such that a first region of the back support has a higher density of crossing lines (as described in more detail below) than a second region of the back support, the first region providing a different degree of cushioning than the second region.
In one embodiment, the first and second layers are the same material and the third layer is formed of a different material. The third layer may provide a degree of cushioning between the first and second layers, and in one embodiment, the third layer is a high loft polyester inlay yarn.
In one embodiment, the knit material is designed to provide a desired cushioning profile that provides support for the lower back and cushion for the upper back. More particularly, the first region may be a pelvic or lumbar region and the second region may be a thoracic region. In one embodiment, the seat back includes a third region that is a shoulder region, the third region having a lower density of crossing lines, and greater cushioning, than the second region. The predetermined pattern may have a variety of shapes and designs, however in one embodiment, the pattern includes formation of a hexagon pattern in the pelvic region, the hexagons are arranged in a hexagonal tessellation and are defined by the crossing lines, and the pattern gradually transitions to partially defined hexagons, and even less partially defined hexagons in the lumbar, thoracic and shoulder regions. In the shoulder regions, the crossing lines may simply appear as dimples in the knit material. The first region, second region and third region may each comprise about one-quarter of the height of the back support.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
An office-type chair 10 is shown in
The back support 12 of the present invention defines a height extending from a base 30 at the bottom edge of the back support 12 to an upper edge 32. The back support also includes first and second lateral edges 34, 36 extending along opposing sides of the back support 12. The back support 12 can be described in terms of a series of regions extending from the upper edge 32 to the base 30. These regions include a thoracic region X (including shoulder region W), lumbar region Y, and pelvic region Z as illustrated in
The back support 12 includes a support frame and a knit support material 40 supported on the frame. In the embodiment illustrated in
An office-type chair 100 with an alternative frame arrangement is shown in
The knit support material 40 extends over and is supported by the frame style selected for the particular chair. In one embodiment the knit support material 40 is formed by a weft knitting style with an inlay material, referred to herein as inlay weft knitting. Details of a weft knit material 40 are shown in
As shown in
In the lumbar region Y, and extending into the thoracic region X, the pattern transitions to a collection of interfitting, partially defined hexagons 58. These hexagons are “partially defined” because the stich lines 60 of these hexagons 58 do not completely surround each of the hexagons 58, and instead the crossing lines 60 form Y-shapes that outline three (3) corners and a portion of each side of the hexagon 58. The partially defined hexagons 58 extend horizontally in rows across the back support 12. Notably, in the illustrated embodiment, the amount of definition of the partially defined hexagons 58 transitions extending vertically upwardly along the back support 12. More particularly, the size of the Y-shaped crossing lines 60 decreases moving upwardly along the back support 12 from the lower portion of the lumbar region Y to the upper portion of the thoracic region X. In one embodiment, the Y-shaped crossing lines 60 have a uniform size across each of the rows of partially defined hexagons 58. The size of the Y-shaped crossing lines decreases as the rows progress upwardly on the back support 12, such that the size of the Y-shaped crossing lines 60 hear the upper portion of the thoracic region X are smaller than the size of the Y-shaped crossing lines 60 in the rows at the bottom of thoracic region X, and the Y-shaped crossing lines 60 at the bottom of the lumbar region Y are smaller than those at the top of the lumbar region Y. In one embodiment, the Y-shaped crossing lines 60 at the top of the thoracic region X and into the shoulder region W are substantially small such that they do not form hexagon shapes but rather appear as crossing points or dimples 62 in the knit material 40.
Referring specifically to
The knit material 40 may incorporate various types of yarn that impart different desired properties to one of more areas of the seat back 12. In one embodiment, the knit material 40 is formed from one type of yarn 42. In another embodiment, however, one area of knit material 40 may be formed from a first type of yarn that imparts a first set of properties, and another area of knit material 40 may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout the knit material by selecting specific yarns for different areas of knit material. The properties that a particular type of yarn will impart to an area of knit material partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the one or more yarns 42 selected for knit material 40 may affect the properties of knit material 40. For example, a yarn 42 forming knit material 40 may be a monofilament yarn or a multifilament yarn. In an embodiment such as that shown in
Inlay or “inlaid” strand 44, as noted above, extends through knit material 40 and passes between the various loops within knit material 40. More particularly, inlaid strand 44 is located within the knit structure of knit material 40, which may have the configuration of a double textile layer in the area of inlaid strand 44, such that the strand extends between layers 50 and 52 and is pinched and trapped between the layers at locations of the crossing lines 56, 60.
As with the yarns forming knit material 40, the configuration of inlaid strand 44 may also vary significantly. In addition to yarn, inlaid strand 44 may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing or cable, for example. In comparison with the yarns forming knit material, the thickness of inlaid strand 44 may be greater, such that the inlaid strand provides a degree of cushioning between the layers 50, 52 of knit material 40. In one embodiment, the inlaid strand 44 is a lofted polyester, and in a more particular embodiment may be a high loft polyester batting. In another embodiment, the materials forming inlaid strand 44 may include any of the materials for the yarn within knit material 44, such as cotton, elastane, polyester, rayon, wool, and nylon. In one embodiment, suitable materials for inlaid strands 44 may also include a variety of engineering filaments, including electrically conductive filaments.
As a result of the zoned pattern of the knit material 40, the support and cushioning characteristics provided by the knit material 40 are different in the different regions W-Z. In general, a higher density or frequency of crossing lines 56, 60 that trap the inlay yarn 44 produces a tighter, less cushioned area of the back support 12. In the illustrated embodiment, the hexagons 54 in the pelvic region Z provide a tighter, less cushioned and more supportive region for the user due to the continuous trapping and pinching of the inlay yarn 44. Transitioning up the seat back 12, the knit material 40 increases in cushioning as the density of crossing lines 56, 60 decreases. The areas of partially defined hexagons 58 trap the inlay yarn 44 less than the hexagons 54, and thus increase the amount of loft and cushioning provided by the inlay yarn 44. As the size of the Y-shaped crossing lines 60 decrease moving up the seat back to the thoracic X and shoulder W regions, the inlay is trapped infrequently and thus provides a high degree of cushioning. A user seated in a chair 10 having this seat back 12 thus feels added support in the lower back region and added cushioning and comfort in the upper back region. These cushioning and support zones can be provided solely by the knit material 40, although optional additional cushioning or support layers can be provided as desired.
Although the seat back 12 is illustrated with a transitioning hexagon pattern, a variety of alternative patterns can be used to provide similar or alternative cushioning and support profiles. For example, the interfitting hexagon pattern may be replaced by a different interfitting pattern, such as squares, rectangles, diamonds, other polygons or irregular shapes. Like the hexagon pattern, these shapes may be arranged to provide less cushioning and greater support in the lower back region and greater cushioning in the upper back region, or they may be arranged to provide a different cushioning profile for a different user request or application.
In one embodiment, the knit material 40 is formed in a single knitting operation on a two-bed flat knitting machine. The knitting machine may be programmable, such that the knit pattern is pre-programmed into the knitting machine and the machine is operated to automatically knit the yarn 42 and inlay yarn 44 according to the program.
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.
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