Patent Application
20050264087
The present invention relates to chairs that include a mesh support surface, and more particularly, to the back rest, armrest, head rest, or seat of such a chair.
Chairs with backs comprising a mesh supporting surface forming a yieldable resilient surface that deforms when sat on have been previously known. It is believed that such structures provide the chair with greater comfort than chairs having backs or seats of a solid construction. One example of a mesh-type chair is found in U.S. Pat. No. 6,059,368 to Stumpf et al.
Because the mesh used to cover seats and seat backs has been made of a single expanse of fabric stretched across a frame, seats and seat backs made from mesh have been limited to being substantially flat. A flat seat and back rest geometry, however, does not provide the user with the appropriate and adequate ergonomic support that a chair needs to provide. For instance, heretofore, mesh back rests have not provided users with lumbar support without the addition of some type of solid support structure. Similarly, heretofore, mesh seats have not provided users with a seat front that tapers down, commonly referred to as a waterfall, without the addition of some type of solid support structure. (See e.g., U.S. Pat. No. 6,604,784 to Bosman, et al.) Consequently, chair manufacturers have not previously been able to provide the benefits of a mesh seat, arm rest, head rest, or back rest in a chair that provides the user with the appropriate ergonomic support.
The missing ergonomic support in conventional mesh chairs is recognized, but attempts to solve the problem have centered on providing a solid structural component. For example, there is a product sold separately (under the name PostureFit™) to add lumbar support structure to the chair described in the Stumpf et al. '638 patent.
The lack of appropriate ergonomic support in conventional mesh chairs is further illustrated by their inability to provide adequate support to the various shapes of users' bodies because of the uncontrolled stretch ability of the mesh. Mesh chairs were believed to provide superior comfort arising from the ability of the mesh to stretch to conform to the shape of the user's body. Such belief failed to recognize, however, that the uncontrolled stretch of the mesh also conformed to unhealthy seating conformations arising from, for example, poor posture, and failed to provide beneficial support where necessary, such as the lumbar area.
In the non-analogous dressmaking art, it is known to use darts, eases, and other assists in order to create contours. Such contours are coordinated with the seam lines. For example, U.S. Pat. No. 3,939,565 to Bush describes such arrangements. However, until now, it has not been known that darts, eases and other assists could be employed to obtain desirable and beneficial contours in a mesh chair component.
Accordingly, it would be advantageous to provide a chair having a mesh support surface where the mesh has a contour that adapts to the user's body. It would be further advantageous to provide such a chair in coordination with a contoured frame for the relevant portion of the chair.
According to the present invention, there is provided a chair having at least one component comprising at least one membranous panel, wherein said component is beneficially contoured to support a user. Said contour can be provided by a component frame supporting said at least one membranous panel or by combining a plurality of panels to form the component.
According to one embodiment of the present invention, there is provided a chair component comprising at least one membranous panel capable of displacement for accommodation of various body shapes.
According to another embodiment of the present invention, the chair component, for example, the seat, arm rest, head rest, or back rest, is comprised of a plurality of panels. Typically, the chair component comprises three or more panels. It is preferred that the chair component of the present invention has no more than ten panels.
In one embodiment of the present invention, each panel is cut, or otherwise formed, in a shape so that when the several panels are combined, together they form a chair component, such as a seat, back rest, or headrest that is capable of beneficially adapting to the user's shape.
The several panels are capable of being combined in a conventional fashion. For example, the panels can be combined by sewing the panels together, by welding them together (such as by sonic welding), or by using an adhesive to bind the panels together. Typically, the chair component surface of the present invention has at least two straight or curvilinear seams. In a preferred embodiment, the seams are curvilinear. It is preferred that the chair component surface of the present invention has fewer than ten seams between panels.
When the several panels are combined, such as in a back rest embodiment, they form a back rest that provides support to the seat user's back. For instance, a back rest made according to the present invention provides a mesh back rest having lumbar support without the necessity of an additional solid structure. Thus, a mesh back rest according to the present invention can have contours without a pad applying pressure to the mesh to achieve beneficial contours.
As used herein, the term “panel contour” refers to a three dimensional shape of a chair component that results from the combination of a plurality of membranous panels. The “panel contour” differs from the three dimensional shape produced by a contoured frame.
According to another embodiment of the present invention, the chair component comprises a single mesh panel covering a contoured component frame. According to this embodiment, the chair component is particularly useful as a chair seat. The seat is thus particularly adapted to be substantially contoured to the various users' body shapes and distribute pressure of the user's lower body.
According to yet another embodiment of the present invention, the chair component comprises a head rest. According to this embodiment, the head rest comprises at least one mesh panel that is contoured to substantially conform to the shape of the user's head. Preferentially, the head rest comprises one or more panels.
According to a further embodiment of the present invention, a chair component, such as a seat, arm rest, back rest or head rest, is formed from a plurality of panels from a membranous material using a contoured component frame.
In some embodiments of the present invention, mesh chair components are combined with other parts to form a chair. For example, a mesh seat according to the invention could be combined with a back rest and a plurality of legs to form a chair. In this embodiment of the invention, one or more components of the chair can be a mesh component according to the invention.
According to another embodiment of the invention, there is provided a chair comprising a chair pedestal, a base mounted on the pedestal, a seat mounted on the base, and a back rest attached to the base. Preferably, the pedestal contains a height adjustment mechanism such as a gas spring. Additionally, the back rest could be pivotally connected to the base. In one such embodiment, the back rest is pivotally connected to the base at a point roughly corresponding to the lumbar region of a user's back. Obviously, such a base would require an upward extension so at to form the pivot connection in that area. Preferably, the back rest comprises at least three membranous panels. Further, the seat can also comprise one or more membranous panels.
The present invention also encompasses further embodiments wherein there is provided a chair having at least one component comprising a contoured mesh panel. In one embodiment, the chair is a swivel chair comprising a base pivotally supporting a seat, optionally including a back, arms, and a head rest, wherein at least one of said seat, back, arms, and headrest is comprised of at least one contoured mesh panel. In another embodiment, the chair comprises four legs stationarily attached to a seat, optionally including a back and arms, wherein at least one of the seat, back, and arms comprise at least one contoured mesh panel.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The present invention provides chair components, and chair made using the components, wherein the chair components include a mesh portion. The mesh chair components, such as chair seats, back rests, head rests, and chair arms, are particularly advantageous in that the mesh is beneficially contoured to provide ergonomic support to the user. Furthermore, the mesh chair components are particularly designed to be adaptable to the various body shapes of multiple users while still providing ergonomic support. The mesh chair components of the invention are particularly useful in that they can be incorporated into a number of various embodiments. For example, one or more of the mesh components of the invention can be incorporated into an office chair (such as including casters), a standard four-leg chair, household seating, public seating facilities (such as stadium seating, movie theatre seating, arena seating, and the like), public transportation seating (such as airplane seating, train seating, bus seating, and the like), professional service seating (such as a dental exam chair), and other similar or related seating apparatuses. The mesh chair components of the invention can also be incorporated into other types of vehicle seating, such as automobile seating. Accordingly, the present invention also encompasses all of the various seating embodiments described above incorporating at least one mesh component as described herein.
In one embodiment of the invention, as shown in
According to this embodiment of the invention, the various panels, 120, 130, and 140, can be adapted to form beneficial contours for receiving various users' body shapes. For example, where a raised contour is desired, as in the lumbar area, the width of right panel 120 and left panel 140, in proportion to center panel 130, is such that the tension on the panels from the force provided by the component frame 110 lifts center panel 130 to the correct contour. In areas of the back rest 100 where it is beneficial to have contours that are less pronounced, such as, for example, in the area of the back rest 100 adaptable for receiving the shoulder area of a user, less tensile force is required. Accordingly, for such areas, right panel 120 and left panel 140 are narrower and center panel 130 is wider. This effect is illustrated in
As provided by the above description, it is therefore possible, according to the invention, to prepare a mesh chair component, such as a back rest, having beneficial contours in desirable areas of the component. Accordingly, the invention allows for preparation of specialized components that are beneficially contoured for special needs users. Additionally, the chair components can be made to have contours in positions, such as generally in the lumbar region, that are beneficial for a wide range of users.
The panels used to make the chair components of the invention, such as the back rest of the embodiment described above, can be made from any conventional membranous fabric. The panels are especially useful as a mesh fabric, such as nylon, polyester, or other synthetic or natural fibers or skins. For example, the panels can be made from leather that has been selectively perforated to substantially emulate a mesh-type material. As such, the perforations could be patterned or unpatterned to impart additional desirable qualities to the panels. Alternatively, the mesh fabric could be comprised of a blend of materials, such as a polyester/nylon blend. Desirably, each of the panels is made from the same type of fabric. In one particular embodiment of the invention, each of the panels is made from a polyester weave mesh.
It is preferable that the material used in preparing the mesh component according to the present invention have a limited stretch ability. Accordingly, the material should have a stretch ability of less than about 10%, preferably less than about 8%, more preferably less than about 6%. It is generally preferred for the material to have a stretch ability on the order of about 5%. Such limited stretch allows for the most effective use of the contours generated according to the invention. The limited stretch allows for maintenance of the support generated by the contours while still providing the comfort of the mesh.
One method of measuring the stretch ability of a membranous material is to take an about two by about twelve inch piece of the membranous material and hang the material vertically. An about twenty pound weight is attached to the bottom of the membranous material. After the weight/material combination has come to equilibrium (for example, after about a half hour), the length of the “stretched” material is measured and compared to the length of the material before the weight was applied. As used herein, a material is of limited stretch ability if the ratio of the length of the “stretched” material to the initial length is less than about 1.10, preferably less than about 1.08, more preferably less than about 1.06. A material of limited stretch ability particularly useful according to the invention has a ratio of around 1.05.
It is further desirable that the membranous material not be pulled too tightly within the outer component frame. Given the benefits provided by the limited stretch ability of the material used in the invention, it is desirable to limit the stretching of the material during manufacture of the chair component, including insertion of the mesh into the outer component frame. In other words, pre-stretching of the material is not required since the limited stretch ability of the material in connection with the contouring of the panels provides sufficient tension without the need for pre-stretching.
Generally speaking, in accordance with a back rest embodiment of the invention, the vertical radius at the lumbar area should be within the range of about 9 inches to about 15 inches. Additionally, the horizontal radius at the lumbar area should be within the range of about 13 inches to about 16 inches and should be within the range of about 22 inches to about 26 inches at the shoulder area of the back rest.
The use of limited stretch material is advantageous over the use of material having a greater stretch ability as it allows for displacement of the material, rather than stretching, which is more accommodative. Mesh material with a stretch ability that is not limited allows the material to conform to the position of the user, which facilitates, or even promotes, poor posture and ergonomically unsound seating. By use of limited stretch material, undesirable positions of the body are not possible as they would be with material having a greater stretch ability. Use of a material having limited stretch ability with modest tension across the component frame, as described above, allows for displacement of the material that accommodates the differing body shapes of various users while maintaining beneficial support. For example, a lumbar contour in a mesh back rest according to the present invention can adjust to the individual back shape and size of various users because the contour can be displaced to correspond to the area of the natural lumbar contour of the user, but the supportive contour of the mesh is maintained, thereby providing support, rather than just stretching without providing needed support.
In the embodiment shown in
The membranous material can be attached to the component frame by any conventional method. One preferred method is by attaching the material, such as by welding or gluing, to a flexible strip, such as a spline, and fitting the combination into a grove formed in the component frame. In one particular embodiment, the membranous material is sewn to a spline. The combination is generally fitted into the groove at a right angle to the direction of the tension on the material. The flexible strip used in attaching the material to the component frame can be made from any material commonly known for such uses, and is desirably a plastic-type extrusion, such as polyethylene or an equivalent.
While the foregoing discussion has mainly described the invention in terms of a back rest, the present invention also lends itself to additional chair components. Accordingly, chairs could be made, according to the invention, having mesh components comprising further chair parts, such as, for example, a chair seat, a chair arm, or a head rest.
Accordingly, the chair seat 200 preferably has an upward curvature 240 toward the front portion of seat 200 and preferably has a downward curvature 250 toward the middle and back of seat 200. Such curvatures can be advantageously designed to receive the lower body of a user in an ergonomically correct sitting position, evenly and comfortably distributing the pressure of the user's lower body. Preferentially, the curvatures of the chair seat 200 are designed for encouraging an ergonomically correct upright posture by the user. According to this embodiment, the panel 220 is stretched side-to-side across component frame 210 with a tension that, preferentially, is greater than the tension applied to the panels of a back rest according to the present invention. A greater tension is preferred in the chair seat embodiment over the back rest embodiment as the chair seat must support the weight of the user. Further, the chair seat generally relies on the particular contouring of the component frame, while in the back rest embodiment, support is also provided by the contours formed by the multi-panel construction.
It is also preferred that the front edge 230 of the chair seat 200 have a “waterfall” effect. This effect can be achieved by appropriate contouring of the front edges of the side portions of component frame 210. For example, it is desirable that the side portions of component frame 210 be radiused downward about 1 to about 1.5 inches at the front portions.
While the foregoing discussion describes the invention in terms of individual chair components, one or more of the components can be incorporated into a chair according to the invention. A chair according to the present invention can include a mesh seat according to the above embodiment. Alternatively, a chair according to the present invention can include a seat comprising a standard cushion and upholstery. Either seat embodiment could be included in a chair comprising a back rest comprising contoured mesh panels as described herein.
The head rest of the present invention is further illustrated in
The rear support pieces 420 and 422 function as two rear leg pieces and are preferentially attached to the front support piece 410 for added stability. In the present embodiment, the rear support pieces 420 and 422 are further adapted for use as arm supports 450 and 452. The rear support pieces 420 and 422 are also useful as supports for the back rest 460. The back rest 460 is preferentially designed to be interchangeable between different chair embodiments. Thus, the back rest 460 is preferentially made according to the embodiments previously described according to the present invention. As shown in
Various modifications to the chair according to
Additional chair embodiments are also envisioned by the present invention. For example, a chair according to the invention could comprise a pedestal, such as one having a plurality of outwardly extending support arms. Such support arms could further comprise components for facilitating movement of the chair, such as casters. Preferentially, the pedestal includes a height adjustment mechanism. In one particular embodiment, the height adjustment mechanism is a gas spring. The pedestal could further comprise a base attached thereto capable of supporting and having attached thereto additional chair components. For example, a back rest according to the present invention could be pivotally connected to the base, such as through a pivot connecting member extending upward from the base. In a particular embodiment, the back rest is pivotally connected to the base at a point roughly corresponding to the lumbar region of a user's back. Further, the base could support a chair seat. In one embodiment, the chair seat is a mesh chair seat according to the present invention. In another embodiment, the chair seat is a conventional chair seat.
The present invention also encompasses further embodiments wherein there is provided a chair having at least one component comprising a contoured mesh panel. In one embodiment, the chair is a swivel chair comprising a base pivotally supporting a seat. The chair can optionally include a back rest, arms, and a head rest, wherein at least one of the chair seat, back rest, arms, and headrest is comprised of at least one contoured mesh panel.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims the benefit of U.S. Provisional Application No. 60/570,611, filed May 13, 2004, which is incorporated herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60570611 | May 2004 | US |
