1. Field of the invention
The present invention relates to an office chair, and more particularly to a molded office chair frame having a mesh fabric support.
2. Description of the Prior Art
There are a variety of office and task chairs available on the market, many of which have tilt control mechanisms. The purpose of the design is to provide a comfortable and ergonomic seating arrangement for the user that allows the user to sit in a variety of positions while providing the necessary support and comfort for the user, regardless of the user's height, weight or other physical characteristics.
Generally, an office or task chair has a base, typically mounted on casters or fixed slides that rest on the floor, and has attached thereto a support column supporting the seat of the chair thereon. Mounted to the support column and between the seat and back of the chair is a tilt control housing, which contains the various controls, knobs and mechanisms for adjusting the height of the chair, the tilt of the chair and various other adjustments so that the user can personalize the chair to his or her own use. The chair may or may not include armrests, which may also be fixed or adjustable in a variety of positions. While there are many mechanisms for controlling the tilt of an office chair, such control mechanisms are generally operated by a spring that is operatively connected to the backrest and driven or activated by movement of the backrest. While the spring can be of any type of construction, such as leaf spring, coil spring, or the like, the tilt of the chair is generally controlled by the user's weight pressing on the back portion of the chair. The chair is generally biased toward an upright condition, such that the user must exert considerable pressure to tilt the backrest to a reclining position. While the amount and ease of tilt may be controlled by adjusting the spring tension, as soon as the user moves forward, the backrest often moves forward thus pushing against the back of the user. Hence, the user feels pressure against his or her back as they recline in the chair, generally giving the feeling that the user is being pushed from the chair.
It is also preferable for the chair to have a lumbar support, which is also adjustable according to the shape or height of the user. There are a variety of lumbar supports available, but most are permanently attached to the chair. Preferably, the lumbar support is easily detachable from the chair such that it can be removed if the user does not desire to have such a support on the backrest. The lumbar support can be attached to either the front or the back of the chair, or can be hidden within the upholstery of the chair. However, when no upholstery is provided it is preferable that the lumbar support have an infinite adjustment on the face of the fabric, which may include mesh fabric, from the lumbar to the pelvic region of the users body.
It is also desired that the armrests be adjustable so that the chair can accommodate a user of any height. While many chairs provide adjustable armrests, the armrests should tilt proportionately to the seat and backrest so that the user remains comfortable at any position of the chair and the user's arms remain level to the floor.
Finally, the fabric of the chair should provide for adequate support for the user's weight, as well as allowing for sufficient airflow around the chair and the user's body to make the user as comfortable as possible. While it is common to use an upholstery covering with a foam interior for comfort and support, an open weave fabric can allow for increased air circulation around the user. The open weave, or mesh, fabric must be sufficiently taut to comfortably support he user's weight, while comfortably conforming to each user's unique body shape.
What is needed then, is a fully adjustable office or task chair that is more accommodating to the user when the user wants to recline and does not try to force the user back into an upright position.
It is therefore an object of the present invention to provide an office or task chair that is adjustable and reclines in a more controlled manner according to the wishes of the user. It is a further object of the present invention to provide an adjustable office chair that reclines as a function of the weight of the user, rather than with the pressure the user exerts on the backrest.
It is a still further object of the present invention to provide an office chair that has full adaptability for any particular user.
Various other objects, features and advantages of the present invention will become readily apparent by reading the following description in conjunction with the drawings, which are shown by way of example only, wherein:
Referring now to the drawings in detail, wherein like reference characters refer to like elements, there is shown in
Preferably, the vertical support column 20 is height adjustable, in a manner well known in the art, and a pair of adjustable armrests 26 are also preferably included. The armrests 26 can be like the adjustable armrest described in applicant's U.S. patent application Ser. No. 10/769,061, which issued as U.S. Pat. No. 6,824,218 on Nov. 30, 2004, which is discussed more hereinafter. Alternatively, the chair 10 need not have armrests 26.
The seat 12 and backrest 14 can each preferably be made from a resiliently flexible mesh material. Both the seat 12 and the backrest 14 can be rotatably attached to the tilt control housing 16 by parallel arm arrangements 30, 32 such that the seat 12 and/or backrest 14 can tilt relative to the tilt mechanism and/or each other, as will be explained in more detail hereinafter in connection with the drawing figures.
As shown best in
A presently preferred embodiment of the tilt control mechanism 35 comprises first 46 and second 48 rotatable shafts, which are preferably hexagonal shaped, and which are connected to first 52 and second 54 pairs of parallel links which rotatably connect opposite sides of the seat 12 to the tilt control mechanism. These first 52 and second 54 pairs of parallel links comprise the first pair 30 of the two pairs of parallel arm arrangements 30, 32 referenced in
The tilt control mechanism 35 includes a torsionally activated tilt spring 58 associated with one of the rotatable shafts 46, 48, and preferably the rear-most shaft 46, which is hereinafter referred to as the drive shaft 46. The second, front-most shaft 48 is referred to as the “follower” shaft 48. Activating the tilt spring 58 from the rearward located drive shaft 46 enables a relatively small moment arm, which is the effective distance between the connection point of the rear pair of parallel arms to the seat 12 and the connection to the drive shaft 46. This relatively small moment arm enables a smaller, lower rate tilt spring 58 to be utilized, in comparison to tilt springs in conventional tilt control mechanisms. The tilt spring 58 can be a conventional torsionally activated spring comprising a rigid outer cylindrical surface 60 that is adhered, e.g., glued, to a cylindrical inner resilient spring element 62. A bore 64, preferably having a hexagonal shape to match the hexagonal shaped drive shaft 46, is provided through the center of the inner resilient spring element 62. The hexagonal shaped drive shaft 46 is disposed through this bore 64 such that rotation of the drive shaft 46 rotates an inner portion of the resilient spring element 62. Since an outer portion of the resilient spring element 62 is fixed, via attachment to the rigid outer surface 60, rotation of the inner portion creates a torsional force in the resilient spring element 62, which provides the resistance to the tilting of the seat 12 and backrest 14.
Referring now to
The tilt spring 58 controls the rate of tilt of the seat 12, and the backrest 14. One end of each of the drive links 52 is operatively secured to the tilt control housing 16 while the second end of each is pivotally mounted to the seat bracket 61.
Additional details of the tilt control mechanism 35 are shown best in
Although the hexagonal shafts 46, 48 could be attached to the housing in any particular order, in the preferred embodiment shown, the drive shaft 46 is mounted towards the rear of the seat 12 and the follower shaft 48 is located towards the front of the seat 12. The follower shaft 48 freely rotates with respect to the housing and is attached thereto by a rotating washer and includes a stop mechanism. The stop mechanism can comprises a washer 77 that is secured to and rotates with the follower shaft 48. The washer 77 can have a shoulders 78 which engage a ledge 79 provided on the inside of the tilt control housing 16. This stop mechanism is not intended to act as a tilt control stop, but is provided to facilitate assembly of the tilt control mechanism 35. The drive shaft 46 can also have a similar stop mechanism, using a similar washer 80 with shoulders 81. However, the shoulders 81 can instead cooperate with a separate stop member 82 which is inserted over the drive shaft 46 and is held in position at the edge of the tilt control housing 16 using a spacer 83. This stop mechanism is a full travel stop which blocks further rotation of the drive shaft 46 at a point at which full travel of the tilt mechanism 35 has been reached.
The drive shaft 46 is secured to, and also passes through, the tilt control housing 16 and is operatively engaged with the tilt spring, which is positioned towards the rear of the tilt control housing 16, as illustrated, in order to shorten the moment arm as much as possible. The drive shaft 46 also has a stop mechanism that engages a ledge provided on the inside of the tilt control housing 16 and acts as one of the stops, or limits, for the tilt control mechanism 35. The tilt spring 58 controls the rate and amount of tilt of the seat 12 and backrest 14. As the drive links 52 rotate, such as when a person sits on the seat, the drive shaft 46 is rotated thereby, which creates a torsional load on the tilt spring 58 by causing the resilient spring member 62 to rotate relative to the rigid outer cylindrical surface 60, which is secured to the inside of the tilt control housing 16 in a manner to generally prevent rotation thereof. When the force causing rotation of the drive shaft 46 is removed, as when the user gets up out of the chair 10, the tilt spring 58 will “unwind,” returning the drive links 52, and thus the seat 12 (and backrest) to the initial upright position as the tilt spring 58 returns to the initial state.
As shown in FIGS. 8 and 11-12, the backrest 14 is connected to the seat 12 via a common connection point with the drive links 52 which connect the seat 12 to the tilt control housing 16. The backrest 14 is also rotatably connected to the tilt control housing 16 via the Y-shaped link 70 described above, which along with the drive links 52 forms the second parallel arm arrangement 32 between the seat 12/backrest 14 and the tilt control housing 16. The single prong end 85 of the Y-shaped link 70 is pivotably connected to the backrest, such as, for example, using a T-shaped projection 72 embedded in the lower middle portion of the backrest 14 which cooperates with a receiver 74 embedded or otherwise set within the end 85 of the Y-shaped link 70. The receiver 74 can have a T-shaped opening in which to pivotably receive the T-shaped projection 72. The receiver can be secured in a the end of the Y-shaped link 70 using, for example fasteners 76, and resilient members 78 can be associated with the end of the T-shaped projection 72 to facilitate pivoting of the T-shaped member 72 in the T-shaped opening in the receiver 74. In this manner, the backrest 14 can pivot sufficiently relative to the end 85 of the Y-shaped link 70 as the backrest 14 tilts.
The opposite, dual pronged end 87 of the Y-shaped link 70 is rotatably attached at two points to a rear-most portion of the tilt control housing 16. Each prong of the dual pronged end 87 of the Y-shaped link 70 is attached at an opposite side of a rear-most portion of the tilt control housing 16, such as using screws 80, or other fasteners which provide a rotatable connection.
The parallel arm arrangements 30, 32 which connect the seat 12 and the backrest 14 to the tilt control housing 16 thus permit rotation, e.g., titling, of the seat 12 and the backrest 14 relative to both the tilt mechanism 35 and to each other. In this manner, the degree of titling of the seat 12 can be varied from the degree of tilting of the backrest 14. Preferably, when the parallel arm arrangements 30, 32 are in the full upright position, as shown in
Referring to
In the upright, at rest position, it appears that the chair 10 may be level. Preferably however, the seat 12 is actually tilted somewhat forward, for example, at approximately 3 degrees of forward tilt. Thus, when viewing the chair 10 with no one seated thereon, the seat 12 generally tilts slightly forward. Although this appears to be counter-intuitive, it has been determined that with the link design of the present invention, as soon as someone sits in the chair, the chair 10 assumes a level or slightly rearward tilt according to the weight of the person seated. As described previously, as the user leans against the backrest 14 to further tilt the chair 10, the parallel arm arrangements 30, 32 are designed to slightly “open up” as the chair 10 tilts back. This is desired so as to prevent the seat 12 and backrest 14 from “closing together,” i.e., a “clam shell” effect, in which the backrest 14 pushes on the back of the user, resulting in an uncomfortable sensation.
Since the drive links 52 and the follower links 54 are operatively connected between the tilt control housing 16 and the seat 12 rather than to the backrest 14, as is the conventional design, the recline of the chair 10 according to the invention is more directly keyed to the weight placed on the seat 12. That is, the tilt of the chair 10 is controlled more by the weight of the user and less by the force applied by the user against the backrest 14 of the chair 10. Thus, as a user moves to an upright position from a reclining position, the backrest 14 does not press significantly on the back of the user, even though the backrest 14 maintains full contact with user's back. In this way, there is a “dwell” in the recline of the chair 10 such that it tends to maintain its position for a short period of time as the user returns to an upright position, thus preventing the feeling of being ejected from the chair 10. Thereby, the chair tilt is “seat driven” rather than “backrest driven.”
Additionally, some degree of potential energy is stored in the tilt spring 58 as a result of the initial downward movement of the seat 12 caused by the weight of the user when he or she sits down in the chair 10. This potential energy is released (as the tilt spring 58 unwinds), and actually assists the user when he or she makes an effort to get up out of the chair 10. Consequently, the chair 10 is more comfortable to both sit in and to arise from. In conventional chairs, in which pushing back against the backrest activates the tilt spring, (i.e. backrest driven) the only “assistance” when arising from the chair is in the form of the backrest pushing against the person's back, which is of no aid at all in standing to an upright position out of the chair. Rather, the backrest pushing against a user's back, either while seated or when arising, is an uncomfortable and unwelcome condition.
The parallel arm arrangements 30, 32 connecting the seat 12 and backrest 14 to the tilt control housing 16 can be designed such that there is a 1.2 to 1 ratio between the tilt of the seat 12 and the tilt of the backrest 14. As the chair 10 is tilted, the rear portion of the seat 12 moves downward relative to the front portion of the seat 12, and the seat 12 back tilts back therewith. Since the tilt of the seat 12 is a function of the user's weight, the tilt is much smoother and more controlled. Also, because the weight of the user is what causes the seat 12 to tilt, there is a gravity assist in the tilting of the chair 10, such that the user does not have to exert a substantial force on the backrest 14 of the chair 10 in order to recline comfortably.
The aforesaid tension adjustment knob 38 is provided in order to increase or decrease the initial tension on the tilt spring 58, i.e., adjust the preload on the tilt spring 58. In order to make it harder or easier (depending upon the weight of the user) for a user to tilt the seat 12 and backrest 14, the user rotates the tensioning knob 38 to either increase or decrease the tension on the tilt spring 58.
As can be seen best in
The tensioning control device is connected to the end of a threaded rod 90 which extends from the tensioning knob 38 and is captured within the tilt control housing 16. The end of the threaded rod 90 cooperates with a nut 92, and washers 94, which operatively engage the threaded rod 90 with the outer rigid outer surface 60 of the tilt spring 58. A retaining pin 96 can insure the nut 92 is never completely removed from the end of the threaded rod 90. In the embodiment shown, a cantilever arm 98, which can be formed integrally with the rigid outer surface 60 of the tilt spring 58, extends outwardly from the surface 60. Rotation of the tensioning knob 38, for example clockwise, causes the nut 92 to be drawn toward the knob 38, and the nut 92 draws the cantilever arm 98 downwards along with it, thus rotating the tilt spring 58 and thereby increasing the tension in the spring 58, making it harder to further compress the tilt spring 58, and thus also making tilting of the seat 12 and backrest 14 more difficult, and slower. Rotating the tensioning knob 38 in the opposite direction permits the tilt spring 58 to return to the initial position, or even beyond the initial setting, thereby reducing the tension, thus making it easier to tilt the seat 12 and backrest 14. Accordingly, by adjusting the tensioning knob 38, the tilt spring 58 can be pretensioned to adjust the degree, and/or ease, of tilting of the seat 12 and backrest 14 portion when a user leans back on the backrest. Since the tilt spring 58 is also connected to seat 12 via the drive shaft 46 connections to the drive links 52, the seat 12, and the backrest 14 because it is connected to the seat 12, will tilt either more or less depending on the user's weight on the seat. In this manner, the tilt is “seat driven.”
Further in regard to the tensioning adjustment, the smaller moment arm resulting from utilizing a parallel arm linkage to rotatably connect the seat 12 to the torsion spring, which enables utilization of a lower rate of tilt spring 58, also enhances the functioning of the tensioning adjustment knob 38. Specifically, because the tilt spring 58 can have lower spring rate, the adjustment of the tensioning knob 38 is much easier, as compared to conventional tilt adjustment mechanisms wherein a heavier rate tilt spring is required, for the simple reason that it is easier to increase the tension on a lighter rate spring than on a heavier rate spring.
Generally, the reason that a heavier rate tilt spring is typically required is that conventional tilting chairs attach the tilt spring to the backrest, not the seat, which results in a longer moment arm, due to the larger distance between the connection to the backrest and the connection to the tilt spring (which is conventionally positioned just under the seat of the chair). The significantly longer moment arm in conventional chairs necessitates a higher rate of tilt spring, because the force exerted on the spring is a function of the load applied at the end of the moment arm and the length of the moment arm. Consequently, the tensioning adjustment for such a higher rate tilt spring requires correspondingly greater force to rotate the tensioning knob to preload the spring. One way to reduce the higher force required to rotate the tensioning knob would be to use a longer cantilever arm extending from the tilt spring. However, a longer cantilever arm can require a larger tilt control housing. Therefore, as can be understood, a significant advantage derives from activating the tilt spring by the seat of the chair instead of the backrest, thereby enabling a much shorter moment arm and thus a lower rate tilt spring.
As a convenience for the user, the tilt housing may have markings, or other indicators, that cooperate with a marker 40 on the tensioning knob 38 to indicate different settings corresponding to different weights of users. The user can use the weight setting approximating his or her weight to quickly and easily rotate the tilt tensioning knob 38 to the appropriate setting. Alternatively, the user can set the tension to a lighter weight, to have the seat 12 recline more quickly; or to a higher weight, to have the seat 12 recline more slowly, according to the user's preference. For example, a person weighing 175 pounds can set the knob 38 to the 175 pound setting, or can set it to a higher or lower weight to make the tilting harder or easier, respectively. Moreover, the full tilt of the seat 12 can be limited according to the position of the tilt lever 41.
Also operatively connected to the drive shaft 46 is a tilt lever 41. When pulled outwardly, the tilt lever 41 can limit, or set, the degree of tilt to which the chair 10 seat 12 and back will recline. The tilt lever 41 is pulled outwardly to release the limiting device.
As best viewed in
In order to provide for added comfort to the user, the backrest 14 preferably includes a lumbar support member. Referring to
As shown in more detail in
As described above, a mesh material 28 is preferably utilized for the seat 12 and backrest 14 material. However, it should be understood that the backrest 14 material could be formed from any type of appropriate, relatively thin material which would permit the cooperating magnetic members of the front pad 202 and rear frame 204 of the lumbar support 200 to be maintained in a cooperating relationship on each side of the material as the lumbar support 200 is adjusted.
Preferably the seat 12 and backrest 14 are comprised of a frame having an elastic mesh fabric 28 attached thereto. Referring to
A presently preferred embodiment of the construction of the seat 12 and backrest 14 are illustrated in FIGS. 8 and 21-26. As shown in
The seat 12 construction and manner of assembly will be described in detail hereinafter, and it is to be understood that the backrest 14 construction and manner of assembly is essentially identical to the seat 12 construction. As such, the backrest 14 construction is not otherwise described in detail hereinafter.
The inner frame 310 is the main structural component, and includes areas for securing the seat 12 to the tilt control housing 16. The outer frame 308 is preferably made integral with the mesh fabric, as described above, and in a manner that will be more fully described below. As the outer frame 308 is placed over the inner frame 310, in a manner similar to that of an embroidery hoop, the mesh fabric 28 is engaged by an upper edge 312 of the inner frame 310. As the outer frame 308 is positioned down over the inner frame 310, the perimeter of the mesh fabric 28 is pulled downward over the upper edge of the inner frame 310, causing the mesh fabric 28 to become tensioned to a desired degree necessary to provide support for a user sitting in the chair 10. The inner frame 310 is then secured in position to the outer frame 308 by a plurality of fasteners, such as mechanical screws or the like, which, for example, pass through pilot holes intermittently molded about the inner frame 310 and threadingly engage screw holes in the outer frame 308, as shown best in
Referring to
As shown in the figures, the outer frame 308 is substantially rigid, and is finally constructed by overmolding a rigid material of exceptional mass and geometry continuously about the perimeter of the mesh fabric 28 and enclosing the rim portion 300, to create a composite outer frame assembly 308 that is not susceptible to expansion or deformation during the frame construction. Preferably, the overmolding material comprises glass filled or non-glass nylon or neoprene or polypropylene, which is injection molded over the rim portion 300 at a temperature which does not exceed about 220° C. This temperature is selected to avoid any appreciable melting of the rim portion 300 during the overmolding process. Since the overmolding does not touch the mesh fabric 28 beyond the rim portion 300, there is no danger of damage to the mesh fabric 28.
The outer frame 309 of the backrest 14 is manufactured in exactly the same manner as that for the outer frame 308 of the seat 12 as just described. Thus, both the seat 12 and backrest 14 comprise a structural inner frame 310, 311 having a cross section of continuous perimeter. The outer frames 308, 309 of both the seat 12 and the backrest 14 likewise have a cross section of continuous perimeter. The shape of the inner 310, 311 and outer 308, 309 frames are preferably complimentary, and can be configured in the injection molding process to any contour. For example, the front of the seat frame may curve downwardly to provide added comfort to the user's thighs while sitting the chair. In addition, a resilient insert, or pad 317, is also preferably provided at the forward edge of the seat frame, between the mesh fabric and the inner frame. This pad further relieves any pressure on the user's legs at the edge of the seat, which greatly improves the comfort of the seat.
Similarly, the backrest 14 may be contoured so as to provide lumbar support for the lower back of the user, as well as for the upper portion of the back near the users shoulders. In whatever shape the seat 12 and backrest 14 are configured, the mesh fabric 28 is stretched from a relaxed condition prior to assembly, to a final stretched condition wherein the fabric 28 is captured between the inner 310, 311 and outer 308, 309 frames, and in which condition the fabric 28 is sufficiently taut to adequately and comfortably support the weight of the user.
The design described above results in the exterior surface of the outer frames 308, 309 defining an exterior surface of the frame of the seat and the backrest, such that a cleaner, more aesthetic exterior surface of the seat and backrest frames is achieved. In some chair designs which utilize a mesh fabric for the backrest and seat supports, the mesh portion is attached to a carrier portion which is then inserted into a channel formed in an exterior surface of the seat and backrest frame members, such that the two seams of the channels which receive the carrier inserts are clearly visible. This can create a less aesthetically appealing chair exterior. In the present manner of attachment, only a single seam between the outer 308, 309 and inner 310, 311 frames is created, which is also only visible from either below the chair or from behind. As can be seen in the drawing figures, the top, front and side views of the chair 10 do not reveal any visible seam between the outer frames 308, 309 and the inner frames 310, 311, giving a cleaner, smoother appearance. Only from the bottom and back view can the single seam between the inner and outer frames be seen.
As is conventional in such chairs 10, a height adjustment mechanism for the vertical column is preferably provided. Referring to
There is described herein is a multi-functional and positionable office or task chair 10 which can accommodate users of varying shapes and sizes in a variety of ways.
Although specific embodiments of the invention are shown in the drawings and described in detail herein, it will be appreciated by those skilled in the art that various modifications and alternatives could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed herein are meant to be illustrative only, and not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/586,951, filed Jul. 8, 2004.
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