Existing chairs with reclining backs often employ complex mechanisms to accommodate reclining motion, and such complex mechanisms are often expensive to manufacture. These complex mechanisms include, for example, separate linkages for the front links of a four bar mechanism, separate components that rotate with respect to one another about set pivot points, and/or springs used to resist reclining forces. In addition, chairs using traditional pivot points limit how the chair may move to a prescribed motion.
A chair system includes a flexible back support member that couples a chair back to a base. The flexible back support member includes a flex zone formed from a flexible material. The flex zone has a first portion defining a first notch that is adapted to narrow as the chair back reclines from an upright position to a reclined position. The flex zone also includes a second portion defining a second notch that is adapted to narrow as the chair back reclines from the upright position to the reclined position. The first portion of the flex zone and the second portion of the flex zone are laterally separated by a gap.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
As shown in
As shown in
In some embodiments, the flexible back support member 26 is unitarily formed with the chair back 12 from a single piece of material through injection molding or through a similar process, although separate, connected components are also contemplated. The chair back 12 shown in
According to some embodiments, each flexible back support member 26, 28 derives its ability to flex and to resist recline from the particular configuration of each flexible back support member 26, 28 as well each from the materials (e.g., the modulus of elasticity of the materials) that form each flexible back support member 26, 28, as discussed below in more detail. As also shown in
The outer portion 32 and the inner portion 36 are laterally separated by a gap 40. In some embodiments, the flexible support member 26 includes a plurality of ridges 42 integrally formed with an upper portion 44 to which the inner portion 36 and the outer portion 32 are also integrally formed. The plurality of ridges 42 longitudinally extend along some or all of the flex zones 25, 35. As used herein, the term “longitudinally” is used to refer to the direction indicated generally by arrow 53 of
In some embodiments, the inner portion 36, the outer portion 32, the upper portion 44 and the ridges 42 are integrally or unitarily formed (e.g., molded or injection molded) of a single material. Exemplary materials include plastics, nylons (e.g., PA6 nylon), polypropylene, and/or other polymers, according to embodiments of the present invention. The materials may be selected in order to provide flexible support members with high flexibility, low modulus of elasticity, and high strength, according to some embodiments. In some embodiments, for example, the flexible back support member 26 is formed of a material having a substantially homogeneous and isotropic modulus of elasticity.
In some embodiments, the flex zones 25, 35 are designed to flex at more than one point to create greater mobility. For example, the flexible support member 26 creates flex zones 25, 35 that may flex near or at any single notch (or plurality of notches), depending on the nature and direction of the reclining force, such that the lower surface of that notch (or notches) contacts its opposing surface (or their opposing surfaces) while the remaining notches remain open (e.g., the lower surfaces of those notches do not contact their opposing surfaces). In some embodiments, the flex zones 25, 35 are located below a seat to create a relative pivot point near the user's hip joint so that the chair back 12 tracks with the user's back during recline.
As the user initially reclines the chair back from an upright position, all of the notches (e.g., notches 34) remain open and the primary force resisting the reclining movement originates from the material used to form the flexible support members as well as the configuration of the flexible support members. For example, the material forming the upper portion 40 and the ridges 44 (as well as the material forming the outer portion 32 and the inner portion 36, e.g., near the notches 34, 38) flex to accommodate the reclining motion of the chair back while contributing the primary resistance, or in some embodiments, essentially all of the resistance, to that motion.
In some embodiments, the notches (e.g., notches 34) are configured to narrow as the back 12 reclines from an upright position (57 in
In some embodiments, the upper portion 40 and/or a section (e.g., section 37 in
When each notch 34, 38 closes or partially closes, the effective area moment of inertia for the flexible support member 26 at the location of the closed notch 34, 38 increases. This creates additional opposing forces that, in some embodiments, stops the reclining motion. In other embodiments, the closing or partial closing of each notch 34, 38 increases the forces opposing the reclining motion without stopping the reclining motion. In those embodiments, the user experiences a reclining resistance which increases in a manner similar to a step function as each of the notches 34, 38 closes. If the notches 34, 38 are too wide for a flexible back support member 26 of a given modulus of elasticity and cross-sectional shape, the flexible back support member 26 will recline too far and/or deform in an undesirable way. If the notches 34, 38 are too narrow, the flexible back support member 26 will not recline far enough. The notches 34, 38 may each have a substantially uniform width with respect to other notches 34, 38 in the upright position (57 in
The seat flex region 70 allows the seat 14 to tilt in a clockwise direction 74 or in a counter clockwise direction 76 (as shown in
In some embodiments, a chair system 10 is formed from three main components: a chair back 12 that includes two flexible back support members (including, e.g., flexible back support member 26) either integrally formed with the chair back or coupled to the chair back, a seat portion 14 that includes a seat flex region 70, either integrally formed with the seat or coupled thereto, and a base (not shown in
According to some embodiments of the present invention, the flexible back support member may be formed of any resilient material, may have many different shapes, and/or may be used without any springs or traditional resistance mechanisms, depending on requirements of the system. A flexible back support member could also be integrated in many different locations on the chair to cause the back to recline, possibly with a different relative pivot point to the seat.
According to some embodiments, the chair system includes various flex zones that effectively decreases the number of parts that have to be assembled, which generally increases ease of assembly and disassembly, product longevity, and product recyclability. In addition, use of the flex zones allows for a more independent motion from one side of the chair system to the other and allows for more visual design freedom and use of lower cost materials and processes (e.g., plastic instead of steel or aluminum castings and mechanical/steel springs). It also provides for a compact and integrated design.
Embodiments of the present invention also provide a more unique solution that does not have to be adjusted for various sized users and that accommodates different postures of any given user. For example, the chair system (e.g., the flexible back support members and/or seat flex region) provides a range of potential flex points that are positioned to react to the location and to the magnitude of a user's center of gravity. For example, reclining motions by a larger user will simply cause the flex zones to bend at a different point than reclining motions by a smaller user. In addition, the chair system will flex differently when the user sits forward on the seat (in which the seat flex region will flex to a greater degree than the flexible back support members) than when the user slouches in the chair (in which the flexible back support members will flex to a greater degree than the seat flex region) or when the user sit in a more upright position (in which the seat flex region and the flexible back support members move more in concert). Furthermore, use of different flexible back support members on either side of the chair back (and/or multiple flex zones in the seat flex region) creates a chair system that flexes in response to a shift in the user's center of gravity from side to side. Thus, in various embodiments the chair system will move with the user through wide range of motions and postures.
The notches in the flexible back support member may also be created by cutting slits in the plastic, by insert molding, by removing a part to form the notches, by assembling a secondary piece to create small notches that could not otherwise be molded, and/or over-molding a soft material that compresses in the notches to have a more constant or linear increase in recline force rather than a “hard stop” (i.e., when the resistance increases in a manner similar to a step function). According to other embodiments of the present invention, the size, shape, and/or composition of the ridges may vary to change the spring rate or increase the moment of inertia of the system. Notch number and size can vary (e.g., one notch or a plurality of notches that close) depending on how tall the flex zones are and on how much back recline is desired. In some embodiments, the flexible back support member creates the reclining motion (e.g., provides effective pivot points) in addition to supplying resistance to the reclining motion.
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.
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