Apparatus and method for manufacturing a fabric suspended seat structure

Abstract

A seat assembly includes a fabric component having a seat surface and a frame including an inner section directly attached to the fabric component. The inner section extends from a middle section having a greater resistance to flexing than the inner section.

Description

[0001] Related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 062,002, filed August 6, 2020, the entire contents of which are incorporated herein by reference. Background of the Invention Technical Field

[0004] Examples of this disclosure generally relate to fabric-suspended seating structures, and more specifically to fabric-suspended seating structures with molded frames. Background Technology

[0006] Seating assemblies (such as office furniture) typically use fabric suspension structures. Typically, a fabric suspension seating structure includes a support frame positioned along the periphery of the fabric. The fabric extends across the support frame to provide a surface for the user to sit on. The fabric is typically secured to a carrier component, which is then attached to the support frame. In some examples, the support frame includes a return flange for supporting the fabric surface under load and a channel for receiving the carrier. The carrier is typically overlaid with a molded, stretched fabric. However, return flanges can be expensive and impractical to manufacture. Some fabric suspension seating structures have eliminated the carrier and return flange, but this type of seating structure can lead to increased stress points and therefore more potential points of failure. Summary of the Invention

[0007] In one aspect, a seat assembly includes a fabric component having a seat surface and a frame, the fabric component having an inner section directly attached to the fabric component. The inner section extends from an intermediate section having greater flexural resistance than the inner section.

[0008] In some examples, the fabric component may be at least partially surrounded by the frame. The fabric component may be configured to extend across the frame in a tensioned state. Further, the fabric component may be at least partially composed of a resin material. In some examples, the seat assembly includes a skirt that may be configured to be molded to the fabric component and have low flexural resistance. The skirt may be at least partially composed of a material with a melting temperature higher than that of the fabric component. Additionally, the skirt may include multiple gaps along its length. Moreover, a movable hinge may be formed between the skirt and the frame.

[0009] In another example, a seat assembly includes a seat member, a frame, and a skirt integrally formed with the frame and the seat member. In some aspects, the skirt may extend along at least a portion of the periphery of the seat member. Further, the skirt may be coupled to an inner section of the frame. Moreover, the flexural resistance of the inner section of the frame may be greater than the flexural resistance of the skirt. A hinge may be formed between the inner section of the frame and the skirt. At least a portion of the seat member may be configured to rotate about the inner section of the frame. In one aspect, the flexural resistance of the skirt decreases in an inward direction from the hinge to the inner edge of the skirt. The skirt may include a plurality of undulating structures along its length. Further, the skirt may decrease in thickness between its inner edge and the frame.

[0010] In yet another example, a method of manufacturing a seat assembly includes: receiving a fabric preform within a first molding block; applying tension to the fabric preform within the first molding block; and attaching a heat shield to a side of the fabric preform exposed to a second molding block. The heat shield may comprise a polyester material. Furthermore, the method may include: moving at least one of the first or second molding blocks toward the other; injecting a liquid thermoplastic material through a cavity in the first molding block to form a frame; removing the first or second molding block from the other molding block; and ejecting the seat assembly. The seat assembly may include the fabric preform and the frame. Additionally, the method may include: discarding excess fabric from the seat assembly; and separating the heat shield from the seat assembly.

[0011] In some respects, the heat shield can be reusable. Furthermore, cooling lines can be formed within the first molded block or the second molded block, or both. Attached Figure Description

[0012] Figure 1 This is a plan view of an example of a seating assembly;

[0013] Figure 2 yes Figure 1 Isometric views of the front, top, left, and right sides of the seat assembly;

[0014] Figure 3 It is along Figure 1 Section line 3-3 cut Figure 1 A cross-sectional view of a portion of the seat assembly;

[0015] Figure 4 It is along Figure 1 Section line 3-3 cut Figure 1 A cross-sectional view of a portion of the seat assembly, in which the fabric component is depicted as transparent;

[0016] Figure 5 It is along Figure 1 Section line 3-3 cut Figure 1 A cross-sectional view of a portion of the seat assembly, in which the fabric is depicted as transparent and under load;

[0017] Figure 6 This is a simplified diagram illustrating a model of the molding process used to manufacture seat components;

[0018] Figure 7 It is similar to Figure 1 A cross-sectional view of a portion of an embodiment of the seat assembly, depicting an alternative embodiment of the skirt;

[0019] Figure 8 It is similar to Figure 7 A cross-sectional view of a portion of another embodiment of the seat assembly, depicting another alternative embodiment of the skirt;

[0020] Figure 9 It is similar to Figure 1 A sectional view of a portion of yet another seat assembly, depicting the skirt gusset and frame gusset; and

[0021] Figure 10 yes Figure 9 A perspective view of a portion of the seat assembly, wherein, for illustrative purposes, the skirt gussets and frame gussets are depicted in dashed lines, as can be seen through a portion of the skirt. Detailed Implementation

[0022] Examples of this disclosure provide a seat assembly comprising a fabric and a frame. A flexible inner portion of the frame is configured to be molded directly to a peripheral segment of the fabric component. The frame may be integrally formed with the inner portion. In some examples, the inner portion of the frame may include grooves, pleats, or reduced thickness along the inner portion. In this way, the seat assembly can distribute stress during loading of the fabric component.

[0023] refer to Figures 1 to 5 In one aspect, a seat assembly 100 is shown, which includes a fabric component 102 or a seat member. The fabric component 102 has a top surface 104 opposite to the bottom surface 106, and the fabric component extends across a frame 108 or frame member such that the fabric component 102 can be stretched or tensioned to provide a top surface 104 or seat surface that is in a suspended state and capable of supporting a user in a seated position.

[0024] like Figure 1 and Figure 2As depicted, fabric component 102 comprises multiple fibers woven or arranged together, wherein all or some of the fibers are formed of a flexible material or resin. For example, fabric component 102 may include knitted components, woven textiles, nonwoven textiles, leather, mesh, suede, and / or combinations of one or more of the aforementioned materials. Fabric component 102 may be formed by warp knitting, weft knitting, plain knitting, circular knitting, and / or other suitable knitting operations. For example, fabric component 102 may have a plain knit structure, a mesh knit structure, and / or a rib knit structure. For example, woven textiles include, but are not limited to, textiles formed by any of a variety of weaving forms (such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weave, and / or double fabric weave). For example, nonwoven textiles include textiles made by dust-free web forming and / or spinning web forming methods. Fabric component 102 may include a variety of materials that may have different properties or visual characteristics. For example, some or all of the fibers in the fabric component 102 may be formed of glass fiber, or thermoplastic material or resin, or a combination thereof. Multiple fibers may be bonded or fastened together and oriented longitudinally relative to each other, and oriented along the longitudinal or transverse length of the frame 108. The melting temperature of the fabric component 102 depends at least in part on the selection or combination of materials or resins of the multiple fibers, which may be configured to have a lower average melting temperature relative to the average melting temperature of the material of the frame 108.

[0025] Continue to refer to Figures 1 to 5 The frame 108 includes an upper surface 110, a lower surface 112, and an outer edge 114 disposed between the upper surface 110 and the lower surface 112. The outer edge 114 is also disposed adjacent to an intermediate section 116, the thickness and shape of which vary along the frame 108. A lower protrusion 118 (see...) Figure 3The inner section 120 extends inward from a portion of the lower surface 112 of the intermediate section 116. More specifically, the inner section 120 is disposed between the fabric component 102 and the intermediate section 116. The frame 108 may be integrally formed of a material or resin, or a combination thereof, which may include an elastic polymer, such as any thermoplastic. For example, thermoplastics may include nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermoset material, including epoxy resin; or any resin-based composite material, including carbon fiber or glass fiber, thereby allowing the frame 108 to adapt to and move in response to forces applied by the user. Frame 108 can be formed from a wide variety of polymeric materials, including, for example, polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), crystalline PET, amorphous PET, polyethylene terephthalate, polystyrene (PS), polyamide (PA), polyvinyl chloride (PVC), polycarbonate (PC), poly(styrene:acrylonitrile) (SAN), polymethyl methacrylate (PMMA), polypropylene (PP), polyethylene naphthalate (PEN), polyethylene furanate (PEF), PET homopolymer, PEN copolymer, PET / PEN resin blend, PEN homopolymer, overmolded thermoplastic elastomer (TPE), fluoropolymer, polysulfone, polyimide, cellulose acetate, and / or combinations thereof.

[0026] refer to Figure 1 and Figure 2 The frame 108 includes a front end 122, a rear end 124, a left end 126, and a right end 128. A longitudinal axis 130 extends from the front end 122 to the rear end 124, further defining a vertical plane bisects the seat assembly 100 and a horizontal plane coplanar with the top surface 104 of the fabric component 102. A transverse axis 132, coplanar with and perpendicular to the longitudinal axis 130, extends from the left end 126 to the right end 128 of the frame 108, further defining a vertical plane bisects the seat assembly 100. Therefore, the intersection of the longitudinal axis 130 and the transverse axis 132 defines the center point C of the seat assembly 100.

[0027] like Figure 1 and Figure 2As depicted, frame 108 is symmetrical about longitudinal axis 130, such that the shape and size of frame 108 at right end 128 is a mirror image of the shape and size of frame 108 at left end 126. The shape and size of frame 108 at front end 122 differ from the shape and size of frame 108 at rear end 124, such that frame 108 is asymmetrical about transverse axis 132. Between left end 126 and rear end 124, frame 108 extends outward and vertically upward to form a first lateral stabilizer 134. Between right end 128 and rear end 124, frame 108 extends outward and vertically upward to form a second lateral stabilizer 136. The first lateral stabilizer 134 bends in a manner similar to a wing, such that the middle section 116 extends from the inner section 120, so that before bending inward and downward to the rear end 124 of frame 108, the outer edge 114 gradually moves away from the horizontal plane of longitudinal axis 130 and from the vertical plane of longitudinal axis 130. Similarly, the curvature of the second lateral stabilizer 136 is similar to that of an airfoil, such that the middle section 116 extends from the inner section 120, and the outer edge 114 gradually increases in spacing above the horizontal plane of the longitudinal axis 130 and outward from the vertical plane of the longitudinal axis 130 before bending inward and downward to the rear end 124 of the frame 108.

[0028] like Figures 1 to 5 As depicted, the thickness and shape of the frame 108 change as it extends around the fabric component 102. The fabric component 102 is tensioned between the front end 122 and the rear end 124 of the frame 108, and further between the left end 126 and the right end 128. Therefore, the fabric component 102 is tensioned in multiple opposite directions and is elastic; these tensioning and elastic effects include equal and opposite force vectors between the fabric component 102 and the frame 108. Thus, the fabric component is molded into the inner segment 120 of the frame 108 to provide a levitation force configured to support the user when the user sits on the top surface 104 of the fabric component 102. Figure 1 and Figures 3 to 5 As depicted, the fabric component 102 is substantially horizontal and flat in its unloaded state. Due to the weight of the user sitting on the top surface 104 of the fabric component 102, the fabric component 102 deflects downward below the horizontal plane of the longitudinal axis 130, as... Figure 2 and Figure 5 As depicted. In this way, the fabric component 102 provides a suspended or hammock-like support to the user sitting on the top surface 104.

[0029] refer to Figure 3 The skirt 140 or the floating component can be molded onto the bottom surface 106 of the fabric component 102. Optionally, due to the molding process, the fabric component 102 can be partially embedded or embedded into the skirt 140 and the frame 108 (see...). Figure 9(See inside.) Continue to refer to... Figure 3 The skirt portion 140 extends from the frame 108, and more specifically, extends inwardly from the inner segment 120 of the frame 108 relative to the center point C. Thus, the skirt portion 140 is partially surrounded by the frame 108, and the fabric component 102 is also partially surrounded by the frame 108. In one aspect, the skirt portion 140 includes a bottom surface 142 opposite to the fabric component 102 and configured to be exposed or uncovered. While the skirt portion 140 and the frame 108 may be integrally formed, the skirt portion 140 is configured to have a lower modulus of elasticity or elasticity than the frame 108.

[0030] The elastic modulus of a material represents the amount of resistance to deformation (e.g., flexural resistance) provided by the material and is generally defined as the slope of the stress-strain curve. In this disclosure, the terms "resistance" and "flexural resistance" are intended to be used in relation to the elastic modulus. Many variables affect the magnitude of the elastic modulus, particularly, for example, material properties, dimensions, force distribution, or rate of deformation. Therefore, the elastic modulus of a material can be increased or decreased by controlling material properties, or by changing dimensions (e.g., thickness or width), or by controlling the magnitude and direction of the applied force, or by changing the duration of the applied force. In some applications, one or more of these variables will be constant, while others remain variable.

[0031] For example, during the loading of the seat assembly 100, a user applies a downward force to the top surface 104 of the fabric component 102, which distributes this downward force across the frame 108 through multiple areas or sections (such as the skirt 140 and the inner section 120) where the fabric component 102 and the frame 108 interact. Because this downward force may fluctuate and the rate of application of the downward force may also fluctuate, these are variables that the skirt 140 and the frame 108 must be designed to accommodate. To this end, material properties, dimensions, proportions, and force distribution can be modified to provide the desired performance during loading.

[0032] Therefore, the skirt 140 is configured to provide better support and stress distribution to the fabric component 102 during loading. When the fabric component 102 flexes downwards during loading, the skirt 140 is configured to resist flexure by providing a levitation force that is opposite in direction and equal in magnitude to the force generated by the weight of a user sitting on the top surface 104 of the fabric component 102. Thus, the material properties, dimensions, and force distribution of the skirt 140 can be adjusted or regulated to achieve the desired flexural resistance during loading, thereby providing the desired resistance and perceived comfort to the user sitting on the seat assembly 100.

[0033] Therefore, the frame 108 and the skirt 140 can be formed of a material that increases flexural resistance during loading, or a material that provides greater flexural resistance to load in low-strain or elongation applications, or a material that provides greater flexural resistance to load in high-strain applications, or a combination thereof. On the other hand, the material properties of the skirt 140 can depend on the desired performance during the molding process in which the fabric component 102 is continuously attached to the skirt 140 for a period of time at a variety of different temperatures (typically at very high temperatures, e.g., above 400°C). The fabric component 102 can be formed of a material with a lower melting temperature than that of the skirt 140. For example, the resin within the material of the skirt 140 may need to be chemically modified to lower the melting temperature, thereby avoiding annealing of the fabric component 102 during the molding process. Thus, the skirt 140 can be formed of a material composition that achieves a balance between desired load-bearing performance and flexural resistance characteristics with desired temperature and adhesion characteristics for molding to the fabric component 102. Alternatively or additionally, the skirt 140 may be made of a material including embedded particles, a substrate, a lattice, or rods.

[0034] Furthermore, the dimensions of the skirt 140 are configured to provide the desired flexural resistance properties. In one aspect, the thickness of the skirt 140 gradually decreases in the inward direction from the inner segment 120 of the frame 108 to the inner edge 144 of the skirt 140 relative to the center point C. Consequently, the flexural resistance of the skirt 140 decreases in the inward direction relative to the center point C. The decrease in flexural stiffness along the skirt 140 can be mathematically defined as a relation to the distance relative to the frame 108, and the mathematical relationship can be linear (e.g., asymptotic or incremental) or nonlinear (e.g., exponential, parabolic, sinusoidal, or logarithmic). For example, the thickness of the skirt 140 at the inner edge 144 may be less than the thickness of the skirt 140 at a location between the inner edge 144 and the inner segment 120. In this way, the thickness dimension of the skirt 140 is controlled to provide a lower modulus of elasticity than the frame 108, thereby achieving the desired flexural resistance. Additionally, the reduced thickness of the skirt 140 may help prevent annealing of the fabric component 102 during the molding process (see...). Figure 6 Preventing annealing of the fabric part 102 during the molding process may require limiting the heating time or duration experienced by the fabric part 102, as well as the level of heat exposed to the fabric part 102, such as whether the heat is applied directly to the fabric part 102 rather than indirectly.

[0035] Still referencing Figure 3A movable hinge 146 exists between the skirt 140 and the inner section 120 of the frame 108. The movable hinge 146 has a smaller flexural resistance than the inner section 120 of the frame 108, allowing the skirt 140 to rotate about the inner section 120 under load. In fact, the frame 108 has increased flexural resistance compared to the skirt 140 and the movable hinge 146, resulting in the inner edge 144 having a smaller flexural resistance than the movable hinge 146, the inner section 120, and the middle section 116 of the frame 108. In this way, the flexural resistance of the skirt 140 decreases in the inward direction relative to the center point C.

[0036] refer to Figure 3 The skirt 140 may further include a plurality of grooves 148 extending along the bottom surface 142. The grooves 148 can further influence stress distribution by effectively reducing the overall thickness of the skirt 140, which in turn reduces its flexural resistance. More grooves 148 can reduce the flexural resistance of the skirt 140 to provide more flexural resistance during loading. For example, one, two, or three grooves 148, or even four or five, or six or seven grooves 148, may be provided along the bottom surface 142 between the movable hinge 146 and the inner edge 144.

[0037] Additionally or alternatively, the size and shape of the grooves 148 can be determined to increase or decrease their effect on the flexural resistance of the skirt 140, for example, by having a larger depth and width that reduces flexural resistance. Furthermore, the grooves 148 can be positioned along the bottom surface 142 relative to each other at consistent incremental distances or at different distances. For example, the grooves 148 can be positioned at intervals ranging from 0.1 mm to 10 mm, or from 2 mm to 6 mm, or even 4 mm to 5 mm. On the other hand, the movable hinge 146 and the first groove can be spaced 5 mm apart, the first and second grooves can be spaced 5 mm apart, the second and third grooves can be spaced 5 mm apart, and the third groove and the inner edge 144 can be spaced 5 mm apart.

[0038] In another example, multiple recesses 148 may be positioned closer to the movable hinge 146 than to the inner edge 144, or multiple recesses 148 may be positioned closer to the inner edge 144 than to the movable hinge 146. In yet another example, there may be one recess 148 equidistant from the movable hinge 146 and the inner edge 144. In yet another example, no recesses 148 may be equidistant from the movable hinge 146 and the inner edge 144. In yet another example, the recess 148 may be curved or arcuate along the bottom surface 142 between the inner edge 144 and the movable hinge 146. Alternatively, the recess 148 may include pleats or undulations of the skirt 140 in the unloaded state, which are configured to unfold or extend in the loaded state. In this embodiment, the skirt 140 may resemble an accordion that unfolds and rotates simultaneously. Furthermore, the recess 148 may be a slot, or a hole, or a recessed portion, or a pit, etc.

[0039] refer to Figure 4 and Figure 5 (Where the fabric component 102 is depicted as transparent), a molded periphery 150, or outer contact area, is defined between the skirt 140 and the fabric component 102. The molded periphery 150 has a surface area defined by multiplying the longitudinal and transverse dimensions of the skirt 140 in contact with the fabric component 102 in an unloaded state, for example, by multiplying the width W of the skirt 140. S With length L S Multiply, where the width W S It is the distance between the movable hinge 146 and the inner edge 144 (see...) Figure 7 ), and length L S It is the distance that the skirt 140 extends along the fabric component 102 around the center point C.

[0040] In one example, the skirt 140 is molded to only one side of the fabric component 102, and more specifically, the upper surface 152 of the skirt 140 is molded to the bottom surface 106 of the fabric component 102, as shown. Figure 4 and Figure 5 As shown. Therefore, the surface area of ​​the molded periphery 150 is less than the total surface area of ​​the top surface 104 or bottom surface 106 of the fabric component 102, and greater than the surface area of ​​the inner section 120 contacting the fabric component 102. In another example, the fabric component 102 is partially embedded within the skirt 140, such that the molded periphery 150 is defined along both the top surface 104 and the bottom surface 106 of the fabric component 102. Therefore, the surface area of ​​the molded periphery 150 is greater than the surface area of ​​the fabric component 102 if it were molded to only a single surface (i.e., the bottom surface 106 or the top surface 104).

[0041] Therefore, the surface area of ​​the molded perimeter 150 is configured to define the force distribution experienced by the skirt 140 and to disperse the force of the user's weight to prevent load-related breakage or failure. If the fabric component 102 is molded only to the inner section 120 and not to the skirt 140, the force generated by the user's weight will be distributed over a much smaller surface area, resulting in higher stress on the fabric component 102 and the inner section 120. Furthermore, the user's comfort is affected by the force distribution and stress experienced by the fabric component 102 due to the surface area of ​​the molded perimeter 150. Therefore, a balance must be struck between the surface area of ​​the molded perimeter 150 and the stress experienced by the fabric component 102. To this end, several features and designs of the skirt 140, or alternative examples thereof, are described herein.

[0042] It is envisioned that the skirt 140 may be irregularly shaped, or its thickness may vary as it extends along the fabric component 102 and around the center point C. Optionally, the skirt 140 may be in continuous contact with the fabric component 102 around the center point C, or one or more interruptions may be provided between the fabric component 102 and the skirt 140. Further, it is envisioned that the skirt 140 may be in continuous contact with the inner segment 120 of the frame 108 along the movable hinge 146. Optionally, the movable hinge 146 may include one or more interruptions or gaps along the movable hinge, such that the contact between the inner segment 120 and the skirt 140 is discontinuous in some areas, as referenced herein. Figure 7 and Figure 8 As described.

[0043] refer to Figure 5 The fabric component 102 is shown in a transitional state between an unloaded state and a loaded state. The skirt 140 can be considered as rotating about the inner section 120 of the frame 108 due to the movable hinge 146. For example, the inner edge 144 of the skirt 140 is displaced downward relative to the horizontal plane of the transverse axis 132 and outward relative to the vertical plane of the longitudinal axis 130. Furthermore, the skirt 140 is shown extending away from the inner section 120, such that the inner edge 144 moves away from the frame 108 and towards the horizontal plane of the longitudinal axis 130. According to the well-known Poisson effect, as the skirt 140 extends, its thickness also decreases. However, as the skirt 140 extends, the groove 148 or undulating structure elongates and increases the distance the skirt 140 extends outward from the inner section 120, thereby allowing the fabric component 102 to continue flexing downward from the horizontal plane of the transverse axis 132. Depending on the number of grooves 148, the thickness variation along the skirt 140, the material properties of the skirt 140, and other factors, the flexural resistance of the seat assembly 100 and the resulting comfort can be adjusted or regulated to achieve the desired performance.

[0044] refer to Figure 6 An example of a molding process 200 is disclosed, which can be used to attach a fabric preform 202 similar to a fabric component 102 to a frame support 204 similar to a frame 108. It is envisioned that the seat assembly 100 can be manufactured in various ways or steps and using various mechanical devices or materials, such as those described in the following patents: U.S. Patent No. 7,618,572 entitled "Method and Apparatus for Manufacturing Load Bearing Fabric Support Structures", U.S. Patent No. 7,677,873 entitled "Apparatus and Method for Molding onto a Stretched Blank", U.S. Patent No. 8,066,501 entitled "Apparatus and Method for Molding onto a Stretched Blank", and U.S. Patent No. 9,156,211 entitled "Apparatus and Method for Manufacturing a Load Bearing Fabric Surface", all of which are assigned to Illinois Tool Works, Inc. Inc., and its entire contents are incorporated herein by reference. It is further envisioned that the seat assembly 100 can be manufactured using various alternative manufacturing methods, such as various types of additive or subtractive manufacturing.

[0045] like Figure 6 The molding process 200 is depicted in a simplified manner with five stages moving from left to right on the page, which will be referred to herein as Stage 1, Stage 2, Stage 3, Stage 4, and Stage 5. Beginning in Stage 1 of the molding process 200, the fabric preform 202 is received by a first molding block 206 and tensioned by a stretching assembly 208. In Stage 1, a second molding block 210 is spaced apart from the first molding block 206, causing the mold to open. Next, Stage 2 involves attaching a heat shield 212 to the side of the fabric preform 202 exposed to the second molding block 210. The heat shield 212 can be reused throughout multiple molding processes 200, and thus, the heat shield is a polyester film made of PET or biaxially oriented PET (BoPET) (trade name Mylar®) or a similar material with similar properties.

[0046] Next, the third stage involves moving the first molding block 206 or the second molding block 210 toward each other to form a molded compression member 214 or a closed mold. During the third stage, a frame support member 204 is formed by injecting a liquid material (e.g., a thermoplastic material) through a mold cavity designed and arranged to be filled with liquid material. Furthermore, cooling lines are installed throughout the molded compression member 214, either in the first molding block 206, the second molding block 210, or both. The cooling lines are designed to remove heat from certain areas or portions of the mold at certain times during the molding process 200. For example, the cooling lines can be designed to create a one-piece frame support member 204 with thinner and more flexible sections or thicker and less flexible sections. Additionally, the cooling lines can be designed to prevent annealing of multiple portions of the fabric preform 202.

[0047] Next, the fourth stage of the molding process 200 includes opening the molding press 214 and removing or expelling the seat assembly 216, which includes the frame support 204 molded to the fabric blank 202, from the stretching assembly 208 of the first molding block 206. During this fourth stage, excess fabric 218 remains in the seat assembly 216, and the heat shield 212 remains fixed to the fabric blank 202.

[0048] Finally, the fifth stage of molding process 200 involves removing excess fabric 218 from seat assembly 216 and separating the heat shield 212 from the fabric preform 202. The heat shield 212 can then be used in another molding process 200, or it can be shipped as part of seat assembly 216 for removal or disposal by the end user. For example, the heat shield 212 may have aesthetic features that make it desirable to include it on the seat assembly when it is shipped to the end user, such as company logos, colors, wording, shapes, or other non-functional purposes.

[0049] Figure 7 and Figure 8 Alternative embodiments of skirts 240 and 340, similar to skirt 140, are depicted; therefore, similar reference numerals are used to indicate similar parts. Figure 7 and Figure 8In the skirt portion 240, 340 is depicted having a plurality of gaps 252 formed along the inner edge 144, each gap 252 extending from the inner edge 144 to a gap end 254 spaced apart between the inner edge 144 and the movable hinge 146. The plurality of gaps 252 at least partially form a plurality of baffles 256 along the skirt portion 140, each baffle 256 extending from the inner edge 144 to a baffle end 258 spaced apart between the inner edge 144 and the movable hinge 146 and also between adjacent gap ends 254. Each gap 252 has a width dimension W. G and length dimension L G And each baffle 256 has a width dimension W B and length dimension L B .

[0050] like Figure 7 The width dimension W of each gap 252 is shown. G The gap can narrow from the inner edge 144 to the gap end 254, and the gap end 254 can be arc-shaped. However, the width dimension W of each gap 252 is... G The distance between the inner edge 144 and the gap end 254 can be constant, such as... Figure 8 The depiction. The envisioned aspect is the width dimension W. G It can be in the range of approximately 4 mm to 60 mm, and each length dimension L G It can be in the range of approximately 4 mm to 130 mm. Furthermore, the width dimension W of each baffle is 256. B It can narrow from the inner edge 144 to the end of the baffle 258, such as Figure 7 As shown. Alternatively, the width dimension W of each baffle 256. B The distance between the inner edge 144 and the baffle end 258 can be constant, such as... Figure 8 As shown. Additionally, the length dimension L B The length dimension L of each gap can be equal to or greater than 252. G The envisioned width dimension W B It can be in the range of approximately 4 mm to 260 mm, and the length dimension L B It can be in the range of approximately 4 mm to 130 mm.

[0051] refer to Figure 7 and Figure 8 Multiple gaps 252 are shown to have similar size and shape, but it is envisioned that each gap 252 may have a different size and shape relative to each other, and also have different... Figure 7 and Figure 8The shape and size are shown. For example, some of the multiple gaps 252 may have a larger width dimension W compared to the remainder of the multiple gaps 252. G and length dimension L G Or width dimension W G It can narrow in different directions. Furthermore, some of the multiple gaps 252 can have gap ends 254 that are flat or angled, rather than curved or linear, or flat or angled in addition to being curved or linear. Similarly, the multiple baffles 256 in... Figure 7 and Figure 8 The baffles are shown to have similar size and shape, but each baffle 256 may have a different size and shape relative to each other. For example, some of the baffles 256 may have a larger width dimension W compared to the rest of the gaps 252. B and length dimension L B Or width dimension W B The gaps 252 and baffles 256 can be narrowed in different directions. Optionally, the gaps 252 and baffles 256 can form a wavy pattern, such as a sine curve or a parabola, along at least a portion of the inner edge 144.

[0052] Continue to refer to Figure 7 and Figure 8 The fabric component 102 extends along the upper surface 260 of the skirt 240 (including each baffle 256) and across each gap 252. In this way, the surface area of ​​the molded perimeter 150 is reduced compared to an embodiment of the skirt 140 without multiple gaps 252. This reduction in the surface area of ​​the molded perimeter 150 is configured to alter the force distribution of the skirt 240 to disperse the forces caused by the user's weight, preventing load-related breakage or failure, while also minimizing any undesirable stiff locations or areas along the molded perimeter 150 that might negatively impact user comfort. Consequently, the multiple gaps 252 and the multiple baffles 256 are sized, shaped, and arranged to improve user comfort while minimizing areas of high stress. Furthermore, Figure 7 and Figure 8 The skirts 140, 240 and 340 depicted can be combined with grooves or undulating structures 148 along the bottom surface 142 and tapered thickness between the movable hinge 146 and the inner edge 144.

[0053] like Figure 9As depicted, any of the skirt portions 140, 240, and 340 may include an undulating structure extending downward from its bottom surface 142, the undulating structure taking the form of a protrusion or skirt gusset plate 360, shaped similarly to a rib or fin. The skirt gusset plate 360 ​​may include a downward-facing bottom side 362 extending between an inner side 364 and an outer side 366, wherein the inner side 364 is closer to and at least partially faces the center point C, and the outer side 366 is farther away from and at least partially faces away from the center point C. The skirt gusset plate 360 ​​may extend at least partially along the bottom surface 142 between the movable hinge 146 and the inner edge 144. Furthermore, the skirt gusset plate 360 ​​may define a height dimension H between the bottom surface 142 and the bottom side 362 of the skirt gusset plate 360. T Furthermore, the skirt gusset plate 360 ​​may have a width dimension W defined between the opposing walls 368. T (See Figure 10 Alternatively, the skirt gusset plate 360 ​​may extend circumferentially or radially along the bottom surface 142 of the skirts 140, 240, 340, and therefore does not have opposing walls 368.

[0054] Additionally or alternatively, similar to the lower protrusion 118, the frame gusset plate 370 may be mounted on the frame 108, such as... Figure 9 As depicted, the frame gusset 370 includes a downward-facing bottom edge 372 extending between an inner edge 374 that is closer to and at least partially facing the center point C, and an outer edge 376 that is farther away from and at least partially facing away from the center point C. The frame gusset 370 may have a mirror-image design compared to the skirt gusset 360. The frame gusset 370 may extend at least partially along the lower surface 112 within the inner section 120 and between the movable hinge 146 and the intermediate section 116. Furthermore, the frame gusset 370 may define a height dimension H between the lower surface 112 and the bottom edge 372 of the frame gusset 370. P Furthermore, the frame gusset plate 370 may have a width dimension W defined between opposing sidewalls 378. P (See Figure 10 Alternatively, the frame gusset plate 370 may extend circumferentially or radially along the lower surface 112, and thus does not have opposing sidewalls 378.

[0055] The skirt gusset plate 360 ​​is preferably configured to mate with the frame gusset plate 370 of the frame 108, and more specifically, the outer side 366 of the skirt gusset plate 360 ​​is configured to mate with the inner edge 374 of the frame gusset plate 370, such as... Figure 10As depicted. This engagement will occur during the loading of the fabric component 102, for example, when a user sits on the fabric component 102 to cause rotation about the movable hinge 146 and thus cause rotation of the skirt gusset plate 360 ​​about the movable hinge 146, as... Figure 9 The arrow pointing in the direction from the skirt gusset plate 360 ​​to the frame gusset plate 370 indicates this. During this rotation, the outer edge 366 of the skirt gusset plate 360 ​​moves toward the inner edge 374 of the frame gusset plate 370 until the two contact, as shown in the image. Figure 10 As depicted. In this way, the frame gusset plate 370 restricts the movement of the skirt gusset plate 360, and thus restricts the movement of the fabric component 102 during load. This prevents excessive flexing of the skirt 140 or alternative skirts 240 and 340, as well as excessive flexing of the frame 108, the inner section 120, and the fabric component 102, thereby preventing failure due to tearing or shearing of these components during load and increasing the service life of the seat assembly 100.

[0056] Furthermore, the skirt gusset plate 360 ​​and the frame gusset plate 370 can be integrally formed with the frame 108 and / or the skirts 140, 240, 340, and are therefore made of the same or similar material as the frame 108 and / or the skirts 140, 240, 340. In this way, when the skirt gusset plate 360 ​​contacts the frame gusset plate 370, each gusset plate can allow a degree of elastic deformation, thus acting like a spring to provide gentle and controlled resistance to further movement. In this way, each of the skirt gusset plate 360 ​​and the frame gusset plate 370 is configured to be compressed in at least one direction and to prevent abrupt or sudden forces from being transmitted to the user sitting on the fabric component 102. Furthermore, the materials and specific locations used in the skirt gusset plate 360 ​​and frame gusset plate 370 help to create a hammock-like suspension for the user sitting on the fabric component 102, while also preventing excessive wear and tear caused by repeated flexing of components (e.g., skirt, frame, and fabric component) during the service life of the seat assembly 100.

[0057] Furthermore, the outer edge 366 of the skirt gusset plate 360 ​​can be angled relative to the horizontal plane of the transverse axis 132, the angle optionally ranging from about 5° to 175°, and the inner edge 374 of the frame gusset plate 370 can also be angled relative to the horizontal plane of the transverse axis 132, the angle optionally ranging from about 5° to 175°. Additionally, the outer edge 366 can be curved or angled, or have other shapes to mate with the inner edge 374 of the frame gusset plate 370. In this way, the outer edge 366 of the skirt gusset plate 360 ​​and the inner edge of the frame gusset plate 370 are each configured to cooperate in a cooperative manner to enhance the user's hammock-like suspension, provide gentle and controlled resistance to further movement, and promote prevention of excessive wear and tear, especially when combined with the material composition and specific location of each gusset plate.

[0058] Furthermore, in some examples, multiple skirt gussets 360 and multiple frame gussets 370 may be arranged along skirt 140 or skirts 240 and 340, and along frame 108, respectively, to uniformly distribute resistance to movement around seat assembly 100. It is contemplated that the multiple skirt gussets 360 and multiple frame gussets 370 may be arranged adjacent to each other, and therefore, each of the multiple skirt gussets and multiple frame gussets is arranged in the same number, such as two, three, four, five, six, seven, eight, nine, or even ten. In some examples, the skirt gussets 360 and frame gussets 370 may be spaced apart from each other, for example, arranged radially spaced around a center point C. Thus, each of the skirt gussets 360 may have different shapes and sizes. For example, some skirt gussets 360 may have larger or smaller height dimensions H. T Or width dimension W T Furthermore, each of the frame gussets 370 can have a different size or shape from one another; for example, some frame gussets 370 may have a different height dimension H. P Or width dimension W P The height or width dimensions of the skirt gussets 360 are larger or smaller than those of the other frame gussets 370. By arranging multiple skirt gussets 360 and multiple frame gussets 370 in such a number and in such dimensions, greater force distribution can be achieved to enhance the user's hammock-like suspension, provide gentle and controlled resistance to further movement, and prevent excessive wear and tear.

[0059] It should be recognized that, with Figure 5 Related aspects and Figure 6 The above description of the molding process applies to any skirt and / or frame component described herein.

[0060] It is envisioned that the seating components described herein can be used in a variety of different applications, such as furniture for residential, commercial, recreational, transportation, or office applications. Alternatively, the described seating components can have broader applications, such as in industrial machinery, outdoor sports equipment, or recreational equipment. For example, the seating components described herein can be used in office furniture, automobiles, aircraft, lawnmowers, boats, and even stadium seating, trampolines, or theaters.

[0061] While various spatial and directional terms such as top, bottom, lower, middle, side, horizontal, vertical, and front may be used to describe embodiments of this disclosure, it should be understood that such terms are used only with respect to the orientations shown in the accompanying drawings. These orientations may be inverted, rotated, or otherwise altered, such that upper is lower, or vice versa, horizontal becomes vertical, and so on.

[0062] Variations and modifications to the foregoing are within the scope of this disclosure. It should be understood that the examples disclosed and defined herein extend to all alternative combinations of two or more individual features mentioned in or apparent from the text and / or drawings. All these different combinations constitute a variety of different alternative aspects of this disclosure. The claims should be interpreted to include alternative examples within the scope permitted by the prior art.

Claims

1. A seat assembly, comprising: A fabric component having a seat surface; A frame that extends around the fabric component and includes an inner section directly molded into the fabric component and an intermediate section extending outward around the inner section; as well as The skirt portion, which is integrally formed with the frame, The intermediate section has a greater flexural resistance than the inner section. The skirt is connected to the inner section of the frame via a movable hinge and extends inward from the inner section of the frame relative to the center of the fabric component. The skirt portion is configured to be molded onto the fabric component.

2. The seat assembly as claimed in claim 1, wherein, The fabric component is at least partially surrounded by the frame.

3. The seat assembly as claimed in claim 1, wherein, The fabric component is configured to extend across the frame in a tensioned state.

4. The seat assembly as claimed in claim 1, wherein, The fabric component is at least partially made of resin material.

5. The seat assembly as claimed in claim 1, wherein, The skirt has less flexural resistance than the frame, and the upper surface of the skirt is molded to the bottom surface of the fabric component, or the fabric component is partially embedded in the skirt.

6. The seat assembly as claimed in claim 5, wherein, The skirt is at least partially made of a material whose melting temperature is higher than that of the material of the fabric component.

7. The seat assembly as claimed in claim 5, wherein, The skirt includes a plurality of gaps along the skirt.

8. The seat assembly as claimed in claim 1, wherein, The skirt includes an inner edge opposite to the movable hinge, and the flexural resistance of the skirt decreases in the direction from the movable hinge toward the inner edge of the skirt.

9. The seat assembly as claimed in claim 1, wherein, The skirt extends along at least a portion of the periphery of the fabric component.

10. The seat assembly of claim 1, wherein, At least a portion of the fabric component is configured to rotate around an inner section of the frame.

11. The seat assembly of claim 1, wherein, The skirt includes multiple undulating structures along the skirt.

12. The seat assembly of claim 1, wherein, The skirt includes an inner edge that is away from the movable hinge, and the skirt's thickness decreases between the inner edge and the frame.

13. A method of manufacturing a seat assembly, the method comprising: The fabric blank is received in the first molding block; Tension is applied to the fabric blank within the first molding block; A heat shield is attached to the side of the fabric blank exposed to the second molding block, wherein the heat shield comprises a polyester material; Move at least one of the first molding block or the second molding block toward the other; Liquid thermoplastic material is injected through the cavity in the first molding block to form a frame and a skirt, wherein the frame extends around the fabric blank and includes an inner section directly molded into the fabric blank, the skirt is integrally formed with the fabric blank, connected to the inner section of the frame by a movable hinge, and is molded onto the fabric blank; Remove the first molding block or the second molding block from the other molding block; Remove the seat assembly, which includes the fabric blank and the frame; Discard excess fabric from the seat assembly; and Separate the heat insulation cover from the seat assembly.

14. The method of claim 13, wherein, The heat shield is reusable.

15. The method of claim 13, wherein, Cooling lines are formed within the first molding block or the second molding block, or within both the first molding block and the second molding block.

Images