Attachment structure for suspended seat

Abstract

The invention relates to an attachment structure for a suspended seat. A seat structure includes a frame, a bracket, and a suspension material. The frame includes first and second side frame members spaced apart in a first direction and defining an opening therebetween. The first and second side frame members have an inner portion facing the opening and an outer portion facing away from the opening, the outer portion including a plurality of first attachment features facing away from the first and second side frame members in the first direction. The bracket includes first and second side bracket members. The first and second side bracket members include a plurality of second attachment features facing the first and second side frame members in the first direction, the plurality of second attachment features engaging the plurality of first attachment features to attach the bracket to the frame. The suspension material is attached to the bracket and extends over the opening in the frame.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional application of Chinese patent application No. 202111348766.5. This application claims priority to U.S. Provisional Patent Application No. 62 / 185,932 filed on June 29, 2015 and U.S. Provisional Patent Application No. 62 / 266,200 filed on December 11, 2015, the entire contents of which are incorporated herein by reference. Background Art

[0002] The present invention relates to a suspended seating structure, such as a chair or stool, including an attachment structure for suspending material and methods of making and using the same.

[0003] A suspended seating structure may have a suspension material secured to a frame over an opening. Typically, the suspension material is tensioned over the opening. When used as a seat, the suspension material should be able to withstand relatively large tensile loads applied by a user. In some seating structures, the suspension material may be captured or captured by the frame. In other seating structures, the suspension material may be coupled to a bracket member that is connected to the frame. Typically, the frame forms a loop around the opening, or has a generally non-linear perimeter, making it difficult to properly size and assemble the bracket to the frame so that the suspension material is subjected to a desired amount of tension over the opening. Similarly, it is difficult to have a desired load bearing capacity for the suspension material. Summary of the invention

[0004] In one embodiment, the present invention provides a seat structure comprising a frame having first and second side frame members spaced apart in a first direction and defining an opening therebetween. The first and second side frame members each have an inner portion facing the opening and an outer portion facing away from the opening. The outer portion includes a plurality of first attachment features facing outwardly away from the first and second side frame members in the first direction. The seat structure also includes a bracket having first and second side bracket members. The first and second side bracket members each include a plurality of second attachment features facing the first and second side frame members in the first direction. The plurality of second attachment features engage the plurality of first attachment features to attach the bracket to the frame. The seat structure also includes a suspension material attached to the bracket and extending above the opening in the frame.

[0005] In another embodiment, the present invention provides a seat structure comprising a frame having first and second transverse frame members spaced apart in a first direction and defining an opening therebetween. The first and second transverse frame members each have an inner portion facing the opening, an outer portion facing away from the opening, and an upper surface disposed between the inner portion and the outer portion. The seat structure also includes a bracket having first and second transverse bracket members spaced apart in the first direction. The first and second transverse bracket members are coupled to the frame. The first transverse bracket member has an upper lip covering the upper surface of the first transverse frame member and a plurality of ribs extending from the upper lip. The plurality of ribs engage the upper surface of the first transverse frame member and support the upper lip above the upper surface of the first transverse frame member. The seat structure also includes a suspension material embedded in the upper lip of the bracket. The upper lip covers a first surface of the suspension material, and the plurality of ribs extend outwardly from a second surface of the suspension material.

[0006] In another embodiment, the present invention provides a seat structure, which includes a frame, which is composed of a plurality of frame members including a first frame member and a second frame member. The frame defines an opening between the plurality of frame members. The first frame member has a boss extending from a first end of the first frame member and a tab movably connected to the boss. The second frame member has a hole formed in an edge of the second frame member and a recess formed in a surface of the second frame member adjacent to the hole. The hole receives the boss to align the first frame member with the second frame member. The recess receives the tab to secure the boss within the hole. The seat structure also includes: a bracket attached to the first frame member and to the second frame member; and a hanging material attached to the bracket and extending above the opening in the frame.

[0007] In another embodiment, the present invention provides a method of assembling a seat structure. The method includes providing a frame having first and second side frame members spaced apart in a first direction and defining an opening therebetween. The first and second side frame members each have an inner portion facing the opening and an outer portion facing away from the opening. Each outer portion includes a plurality of first attachment features facing outwardly away from the first and second frame members in the first direction. The method also includes providing a bracket having first and second side bracket members. The side bracket members each include a plurality of second attachment features facing the first and second side frame members in the first direction. The method also includes: attaching a suspension material to the bracket; and engaging the plurality of second attachment features with the plurality of first attachment features to attach the bracket to the frame so that the suspension material extends above the opening in the frame.

[0008] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1A is a perspective view of a chair according to some embodiments of the present invention.

[0010] Figure 1B is a perspective view of another chair according to some embodiments of the present invention.

[0011] Figure 2A yes Figure 1A Perspective view of the chair with the brackets and hanging material removed.

[0012] Figure 2B yes Figure 1B Perspective view of the chair with the brackets and hanging material removed.

[0013] Figure 3 yes Figure 2B An exploded perspective view of a portion of the frame of the chair shown in FIG.

[0014] Figure 4 This part of the frame is along Figure 3 A cross-sectional view taken along section line 4-4.

[0015] Figure 5 It is part of the chair's frame, brackets and hanging material. Figure 1B A cross-sectional view taken along section line 5-5.

[0016] Figure 6 It is part of the chair's frame, brackets and hanging material. Figure 1B A cross-sectional view taken along section line 6-6.

[0017] Figures 7A-7D Brackets and frames according to some embodiments of the present invention are shown.

[0018] Figures 8A-8B A bracket according to some embodiments of the present invention is shown.

[0019] Figures 9A-9B is an enlarged view of a bracket including ribs according to some embodiments of the present invention.

[0020] Figures 10A-10C Showing bracket with and without ribs subject to load Figures 11A-11B Brackets and frames according to some embodiments of the present invention are shown.

[0021] Figures 12A-12B Brackets and frames according to some embodiments of the present invention are shown.

[0022] Figures 13A-13B Brackets and frames according to some embodiments of the present invention are shown.

[0023] Figures 14A-14C Brackets and frames according to some embodiments of the present invention are shown.

[0024] Figures 15A-15C Brackets and frames according to some embodiments of the present invention are shown.

[0025] Figures 16A-16B A bending bracket and a bending frame according to some embodiments of the present invention are shown.

[0026] Fig.17 is an exploded view of a stool according to some embodiments of the present invention.

[0027] Figures 18A-18C yes Fig.17 View of stool.

[0028] Fig.19A —19E shows a method of manufacturing a bracket according to some embodiments of the present invention.

[0029] Fig. 20 is a perspective view of the tool used to attach the bracket to the frame. DETAILED DESCRIPTION

[0030] Before explaining any embodiments of the invention in detail, it should be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or shown in the following drawings. The invention is capable of other embodiments and can be practiced or carried out in various ways.

[0031] Figure 1A-1B A seat structure 10A, 10B embodying the present invention is shown. The seat structures 10A, 10B shown are office chairs, which are also commonly referred to as work chairs. Each seat structure 10A, 10B includes a base 14, a support column 18, a tilt mechanism 22 ( Figure 2A ,2B), frame 26A,26B( Figure 2A , 2B), armrests 28A, 28B, brackets 30A, 30B and suspension materials 34A, 34B. In the illustrated embodiment, the base 14, support column 18 and tilt mechanism 22 are identical, and the frames 26A, 26B, brackets 30A, 30B and suspension materials 34A, 34B are substantially similar. Specifically, Figure 1A The frame 26A, bracket 30A and suspension material 34A of the seat structure 10A shown in FIG. 1 are configured to form a chair having a relatively low backrest 36A, while Figure 1BThe frame 26B, bracket 30B and suspension material 34B of the seat structure 10B shown in FIG. 1 are configured to form a chair having a relatively high backrest 36B. Other differences between the seat structures 10A, 10B will be discussed below.

[0032] like Figure 1A-1B As shown in , each base 14 includes a rigid substructure 38, an outer cover 42 and a plurality of casters 46. The rigid substructure 38 supports the weight of the seat structure 10A, 10B. The rigid substructure 38 includes five arms 50 surrounding a central hub 54. One of the casters 46 is attached to the distal end of each of the arms 50. The rigid substructure 38 is made of metal (e.g., aluminum, steel, etc.), heavy plastic or composite material. The outer cover 42 is positioned above the rigid substructure 38. In some embodiments, the rigid substructure 38 and the outer cover 42 can be integrally formed of metal or rigid plastic. In some embodiments, the outer cover 42 can be overmolded onto the rigid substructure 38.

[0033] like Figure 1A-1B and Figure 2A-2B As shown in FIG. 1 , the support column 18 of each seat structure 10A, 10B extends vertically from the base 14. The support column 18 includes a lower end 62, an upper end 66, a telescoping section 70, and an actuator 74. The lower end 62 of the support column 18 is rotatably attached to the base 14. The upper end 66 of the support column 18 is attached to the reclining mechanism 22. The support column 18 includes a telescoping section 70 that is adjustable to change the height of the seat 32A, 32B. The actuator 74 can be attached to the support column 18 by means of a cable guide and a cable.

[0034] like Figure 2A-2B As shown in FIG. 1 , the tilt mechanism 22 of each seat structure 10A, 10B is coupled to the upper end 66 of the support column 18 opposite the base 14 and to a portion of the frame 26A, 26B. The tilt mechanism 22 is configured to allow the frame 26A, 26B to pivot (eg, tilt) relative to the support column 18.

[0035] like Figure 2A-2BAs shown in FIG. 1 , the frame 26A, 26B of each seat structure 10A, 10B is supported above the base 14 by the reclining mechanism 22. Each frame 26A, 26B includes a plurality of frame members. More specifically, each frame 26A, 26B includes a first side frame member 78A, 78B, a second side frame member 82A, 82B, a first transverse frame member 86A, 86B, and a second transverse frame member 90A, 90B. The first side frame member 78A, 78B and the second side frame member 82A, 82B are spaced apart along a first axis 94A, 94B and define an opening 98A, 98B therebetween. The first transverse frame member 86A, 86B and the second transverse frame member 90A, 90B are spaced apart along a second axis 106A, 106B that is substantially perpendicular to the first axis 94A, 94B. The first transverse frame member 86A, 86B and the second transverse frame member 90A, 90B span the opening 98A, 98B and are connected to the first side frame member 78A, 78B and the second side frame member 82A, 82B. The first side frame member 78A, 78B, the second side frame member 82A, 82B, the first transverse frame member 86A, 86B and the second transverse frame member 90A, 90B each have an inner portion 99A, 99B facing the opening 98A, 98B and an outer portion 100A, 100B facing away from the opening 98A, 98B. The support surface 101A, 101B extends between the inner portion 99A, 99B and the outer portion 100A, 100B. A plurality of first attachment features 102A, 102B are arranged along the outer portion 100A, 100B so that the plurality of first attachment features 102A, 102B surround the outer periphery of the frame 26A, 26B. The plurality of first attachment features 102A, 102B face outwardly away from the first side frame members 78A, 78B, the second side frame members 82A, 82B, the first transverse frame members 86A, 86B, and the second transverse frame members 90A, 90B. Figure 5 , Figure 6 and Figures 7A-7D As shown in FIG. 1 , the first attachment features 102A, 102B are teeth 104A, 104B.

[0036] In the illustrated embodiment, the first side frame members 78A, 78B, the second side frame members 82A, 82B, the first transverse frame members 86A, 86B and the second transverse frame members 90A, 90B form a closed loop or ring. In some embodiments, the ends of some or all of the frame members 78A, 78B, 82A, 82B, 86A, 86B, 90A, 90B are bent to provide a relatively smooth transition between these frame members and provide rounded corners for the frames 26A, 26B. Although the frames 26A, 26B are shown to be formed by separate frame members, in other embodiments, the frames 26A, 26B can be formed as a single homogenous unit. In some embodiments, the frames 26A, 26B are made of thermoplastics filled with glass and unfilled with glass.

[0037] In the illustrated embodiment, each frame 26A, 26B is contoured to define both the seat 32A, 32B and the backrest 36A, 36B. In other words, each frame 26A, 26B defines a continuous seat and backrest. The lower portions of the first transverse frame members 86A, 86B and the side frame members 78A, 78B, 82A, 82B are generally flat to define the seat 32A, 32B, while the upper portions of the second transverse frame members 90A, 90B and the side frame members 78A, 78B, 82A, 82B are generally flat to define the backrest 36A, 36B. In other embodiments, each frame 26A, 26B may be generally flat and only define the seat 32A, 32B. In further embodiments, each frame 26A, 26B may be generally flat and only define the backrest 36A, 36B.

[0038] like Figure 2B , Figure 3 and Figure 4 As shown in , the frame 26B includes a third transverse frame member 108B. The third transverse frame member 108B includes an elongated body 110B, a first arm 114B and a second arm 118B. The first arm 114B and the second arm 118B are substantially perpendicular to the elongated body 110B. In some embodiments, the curved corner extends between the elongated body 110B and the first arm 114B and the second arm 118B. The first arm 114B and the second arm 118B of the third transverse frame member 108B are configured to engage the first side frame member 78B and the second side frame member 82B, respectively. When the third transverse frame member 108B is engaged with the first side frame member 78B and the second side frame member 82B, the elongated body 110B of the third transverse frame member 108B is vertically spaced apart from the second transverse frame member 90B and is substantially above the second transverse frame member 90B to form a higher backrest 36B.

[0039] In the illustrated embodiment, the third transverse frame member 108B is secured to the first side frame member 78B and the second side frame member 82B by a snap-fit ​​connection. Figure 3 and Figure 4 As shown in , the first arm 114B and the second arm 118B are substantially similar, and the first side frame member 78B and the second side frame member 82B are substantially similar. As such, only the first arm 114B and the first side frame member 78B will be described in detail below. Similar reference numbers are used to refer to similar components on the second arm 118B and the second side frame member 82B.

[0040] like Figure 3 As shown in , the first arm 114B includes a boss 122B extending from the end of the first arm 114B and a tab 126B movably coupled to the boss 122B. The boss 122B has a cross-section that is smaller than the cross-section of the remainder of the first arm 114B. The tab 126B is surrounded by a slot 130B so that the tab 126B cantilevered over the boss 122B and can move (e.g., flex) relative to the boss 122B. The tab 126B also includes an enlarged distal portion 138B.

[0041] See also Figure 3 and Figure 4 , the first side frame member 78B has a hole 142B formed in an edge of the first side frame member 78B and a recess 146B formed in the surface of the first side frame member 78B adjacent to the hole 142B. The hole 142B is shaped to receive the boss 122B. The recess 146B is formed in the interior surface of the first side frame member 78B that partially defines the hole 142B. In the illustrated embodiment, the recess 146B is a through hole that also extends through the exterior surface of the first side frame member 78B. In other embodiments, the recess 146B can be a recessed portion formed in the interior surface of the side frame member 78B. The recess 146B is configured to receive the enlarged distal portion 138B of the tab 126B. Specifically, the boss 122B slides into the hole 142B until the enlarged distal portion 138B of the tab 126B is aligned with the recess 146B, where the tab 126B snaps outward (due to the bias of the material) and enters the recess 146B, thereby securing the frame members 78B, 108B together. The boss 122B with the tab 126B and the hole 142B with the recess 146B thereby connects the third lateral frame member 108B to the first and second side frame members 78B, 82B without additional fasteners or tools. In an alternative configuration, the first side frame member 78B can include the boss 122B and the tab 126B, and the first arm 114B can include the hole 142B and the recess 146B.

[0042] like Figure 2A and Figure 2BAs shown in , the frame 26A, 26B of each seat structure 10A, 10B includes a support assembly 150A, 150B to support the frame 26A, 26B. The support assembly 150A, 150B includes a central spine 154A, 154B, a first lower support member 158A, 158B, and a second lower support member 162A, 162B. The central spine 154A, 154B is generally Y-shaped and includes a first arm 166A, 166B, a second arm 170A, 170B, and a third arm 174A, 174B. The first arm 166A, 166B is coupled to the second transverse frame member 90A, 90B. In some embodiments, the first arm 166A, 166B is integrally formed with the second transverse frame member 90A, 90B. The second arm 170A, 170B and the third arm 174A, 174B of the central spine 154A, 154B extend below the seat 32A, 32B and are coupled to the reclining mechanism 22 via the second lower support member 162A, 162B. The first lower support member 134A, 134B and the second lower support member 162A, 162B extend laterally below the first side frame member 78A, 78B and the second side frame member 82A, 82B. The first lower support member 158A, 158B and the second lower support member 162A, 162B include upwardly curved ends that are configured to be joined to the first side frame member 78A, 78B and the second side frame member 82A, 82B.

[0043] See also Figures 7A-7D, the teeth 104A, 104B are evenly spaced along the outer portion 100A, 100B of the frame 26A, 26B. Each tooth 104A, 104B has a proximal end 200A, 200B and a curved distal end 204A, 204B, defining a length 208A, 208B therebetween. The teeth 104A, 104B may have the same length. The length 208A, 208B of the teeth 104A, 104B is less than the thickness 212A, 212B of the frame 26A, 26B. The teeth 104A, 104B are tapered so that the proximal end 200A, 200B of each tooth 104A, 104B has a first width 216A, 216B, and the curved distal end 204A, 204B of each tooth 104A, 104B has a second width 220A, 220B that is shorter than the first width 216A, 216B. The teeth 104A, 104B have a substantially constant height 224A, 224B. There are uniform spacings 228A, 228B between adjacent teeth 104A, 104B. The spacings 228A, 228B between adjacent teeth 104A, 104B are substantially equal to the first width 216A, 216B of the teeth 104A, 104B. The first width 216A, 216B of the teeth 104A, 104B may be between about 4 mm and about 25 mm. The length 208A, 208B of the teeth 104A, 104B may be between about 4 mm and about 8 mm. The height 224A, 224B of the teeth 104A, 104B may be between about 3 mm and about 5 mm. The spacing 228A, 228B between the teeth 104A, 104B may be between about 4 mm and about 25 mm. The thickness 212A, 212B of the frame 26A, 26B may be between about 6 mm and about 12 mm. The teeth 104A, 104B may have a slight taper along the length 208A, 208B in both the height 224A, 224B and width dimensions.

[0044] like Figure 1B As shown in, the armrest 28B can be ring-shaped and include an opening 232B. The armrest 28B can include an inner portion 236B facing the opening 232B and an outer portion 240B facing away from the opening 232B. The support surface 244B can extend between the inner portion 236B and the outer portion 240B. In some embodiments, a plurality of first attachment features 102A, 102B (e.g., teeth) are also arranged along the outer portion 240B of the armrest 28B. In other words, the construction of the armrest 28B can be similar to the frame 26B, but with different shapes and sizes. The armrest 28B can be engaged with a suitable bracket by means of a suspension material, similar to the brackets 30A, 30B and the suspension materials 34A, 34 described below.

[0045] like Fig. 8A and Figure 8BAs shown in FIG. 1 , each bracket 30A, 30B includes a first side bracket member 248A, 248B, a second side bracket member 252A, 252B, a first transverse bracket member 256A, 256B, and a second transverse bracket member 260A, 260B. The first side bracket member 248A, 248B and the second side bracket member 252A, 252B are spaced apart along a first axis 266A, 266B and define an opening 268A, 268B therebetween. The first transverse bracket member 256A, 256B and the second transverse bracket member 260A, 260B are spaced apart along a second axis 279A, 279B that is substantially perpendicular to the first axis 266A, 266B. The first lateral bracket member 256A, 256B and the second lateral bracket member 260A, 260B span the opening 268A, 268B and are connected to the first side bracket member 248A, 248B and the second side bracket member 252A, 252B. The first side bracket member 248A, 248B, the second side bracket member 252A, 252B, the first lateral bracket member 256A, 256B and the second lateral bracket member 260A, 260B each include an inner portion 270A, 270B facing inwardly toward the opening 268A, 268B and an outer portion 272A, 272B facing away from the opening 268A, 268B. The upper support surface 274A, 274B and the lower support surface 276A, 276B extend between the inner portion 270A, 270B and the outer portion 272A, 272B.

[0046] like Fig. 7A and Figure 7B As shown in , each bracket 30A, 30B also includes a plurality of second attachment features 262A, 262B arranged along the inner portion 270A, 270B. The plurality of second attachment features 262A, 262B face the first side frame members 78A, 78B, the second side frame members 82A, 82B, the first transverse frame members 86A, 86B, and the second transverse frame members 90A, 90B. The plurality of second attachment features 262A, 262B are arranged along the inner portion 270A, 270B of the bracket 30A, 30B so that the plurality of second attachment features 262A, 262B surround the inner periphery of the bracket 30A, 30B. As shown in Figure 6-7D, the second attachment feature 262A, 262B is an orifice 264A, 264B. In the illustrated embodiment, the orifice 264A, 264B is a straight-through opening. In other embodiments, the second attachment feature 262A, 262B can be a cavity. The bracket 30A, 30B is attached to the frame 26A, 26B by engaging a plurality of first attachment features 102A, 102B with a plurality of second attachment features 262A, 262B. In some embodiments, the first attachment feature 102A, 102B on the frame 26A, 26B can be an orifice, and the second attachment feature 262A, 262B on the bracket 30A, 30B can be a tooth.

[0047] In the illustrated embodiment, the first side bracket members 248A, 248B, the second side bracket members 252A, 252B, the first transverse bracket members 256A, 256B and the second transverse bracket members 260A, 260B form a closed circle or ring. The illustrated bracket members 248A, 248B, 252A, 252B, 256A, 256B, 260A, 260B are integrally formed as a single homogenous unit. The brackets 30A, 30B may be formed of thermoplastic elastomers, thermoplastic polyurethanes and / or unfilled elastomers. In other embodiments, the brackets 30A, 30B may be formed of discrete frame members.

[0048] like Fig. 8A and Figure 8B As shown in FIG. 1 , each bracket 30A, 30B includes an upper support surface 274A, 274B and a lower support surface 276A, 276B extending between the inner portion 270A, 270B and the outer portion 272A, 272B. The upper support surface 284A, 284B is bent downward from its inner portion to the outer portion, as shown in FIG. Figure 5 –6. The upper support surface 284A, 284B includes an upper lip 280A, 280B having a portion extending inwardly and covering the top of the hanging material 34A, 34B and the frame 26A, 26B. The lower support surface 288A, 288B can engage the support surface 101A, 101B of the frame 26A, 26B. The first lateral bracket member 256A, 256B and the second lateral bracket member 260A, 260B include a lower lip 286A, 286B extending outwardly. The bracket 30A, 30B also includes a channel 304A, 304B that opens outwardly and away from the opening 268A, 268B of the bracket 30A, 30B. As shown in FIG. Figure 5-6 and Figures 7A-7DAs shown in, in some embodiments, the first side bracket member 248A, 248B, the second side bracket member 252A, 252B, the first lateral bracket member 256A, 256B, and the second lateral bracket member 260A, 260B can each include an upper lip 280A, 280B and a lower lip 286A, 286B. The upper lip 280A, 280B and the lower lip 286A, 286B are vertically spaced apart. The upper lip 280A, 280B and the lower lip 286A, 208B are connected together by a plurality of spaced apart struts 314A, 314B. The struts 314A, 314B define the apertures 264A, 264B. See Figure 7B In some embodiments, the apertures 264A, 264B are defined by upper and lower landing points 380A, 380B, 384A, 384B and spaced apart struts 314A, 314B. The spaced apart struts 314A, 314B help maintain the shape and integrity of the apertures 264A, 264B in response to tension in the brackets 30A, 30B when they are engaged with the frames 26A, 26B and in response to cycles of external loading of the suspension material 34A, 34B (e.g., by a user sitting down).

[0049] like Fig. 7A , Figure 7B and Fig.7D As shown in FIG. 1 , the apertures 264A, 264B are evenly spaced along the channels 304A, 304B. The depth of the apertures 264A, 264B is the same as the depth 326A, 326B of the pillars 314A, 314B. Each aperture 264A, 264B has a height 332 and a width 336 configured to receive one of the teeth 104A, 104B. Fig. 7A As shown in FIG, when the bracket 30A, 30B is engaged with the frame 26A, 26B, the distal ends 204A, 204B of the teeth 104A, 104B are flush with the outer ends 340A, 340B of the posts 314A, 314B so that the distal ends 204A, 204B of the teeth 104A, 104B are disposed within the channels 304A, 304B. The channels 304A, 304B thus isolate or space the distal ends 204A, 204B of the teeth 104A, 104B inwardly from the outer portions 272A, 272B of the bracket 30A, 30B, thereby protecting the teeth 104A, 104B from impact damage. Figure 5 , Figure 6 and Fig. 7A As shown in FIG. 1 , the distal ends 204A, 204B of the teeth 104A, 104B of the first attachment feature 102A, 102B are visible through the apertures 264A, 264B on the side of the bracket 30A, 30B facing outwardly away from the openings 268A, 268B. In other words, the teeth 104A, 104B are visible along the outer perimeter of the seat structure 10A, 10B to form a "zipper-like" appearance ( Figure 5 –6).

[0050] like Figure 5-6 As shown in , the suspension material 34A, 34B is attached to the bracket 30A, 30B and extends above the opening 98A, 98B defined by the frame 26A, 26B. The suspension material 34A, 34B can be made of a woven or knitted material, such as an elastomeric material, a fabric, or a molded polymer material. In some embodiments, the suspension material 34A, 34B forms a continuous seat and backrest of the seat 32A, 32B, the backrest 36A, 36B, or the seat structure 10A, 10B. In some embodiments, the frame 26B, the bracket 30B, and the suspension material 34B also form an armrest 28B.

[0051] The suspension material 34A, 34B is coupled to the bracket 30A, 30B. In the illustrated embodiment, the suspension material 34A, 34B is molded into the bracket 30A, 30B. In other embodiments, the suspension material 34A, 34B may be coupled to the bracket 30A, 30B by bonding, adhesives, mechanical fasteners (e.g., nails, screws, etc.), or the like. In embodiments where the suspension material 34A, 34B is molded into the bracket 30A, 30B, the edge 356A, 356B of the suspension material 34A, 34B is captured within the bracket 30A, 30B so that the upper lip 280A, 280B of the bracket 30A, 30B covers the edge 356A, 356B of the suspension material 34A, 34B.

[0052] When the brackets 30A, 30B are attached to the frames 26A, 26B, the suspension material 34A, 34B is stretched over the openings 98A, 98B defined by the frames 26A, 26B so that the suspension material 34A, 34B is tensioned. Fig. 9A and Fig. 9B ) is formed between the first side bracket members 248A, 248B and the second side bracket members 252A, 252B.

[0053] like Fig. 9A and Fig. 9B As shown in FIG. 1 , the brackets 30A, 30B include a plurality of ribs 360A, 360B. The ribs 360A, 360B are positioned along the lower surface 288A, 288B of the upper lip 280A, 280B and engage the support surface 101A, 101B of the frame 26A, 26B. The ribs 360A, 360B are generally positioned along portions of the brackets 30A, 30B that may experience point loading, such as along the first transverse bracket members 256A, 256B (e.g. Fig. 9A and Fig. 9B360B) or positioned along the armrest 28B). Each of the plurality of ribs 360A, 360B is generally shaped as a conical framework. The ribs 360A, 360B may collapse or deflect under load. The ribs 360A, 360B are made of a resilient material and act as springs. The ribs 360A, 360B are formed as discrete elements so that only the ribs 360A, 360B in close proximity to the applied load 364 deflect ( Fig. 9B ). Ribs 360A, 360B extend above tension lines 348A, 348B ( Fig. 9B ) and supports a portion of the suspension material 34A, 34B above the tension line 348A, 348B to form a positive cushioning curvature above the tension line 348A, 348B. When the suspension material 34A, 34B is subjected to the applied load 364, the ribs 360A, 360B prevent the suspension material 34A, 34B from contacting the support surface 101A, 101B of the frame 26A, 26B. The ribs 360A, 360B are made of an elastic material, such as rubber or silicone. Fig. 8A As shown in FIG. 5 , the width 362A, 362B of the upper lip 280A, 280B and the length of the rib 360A, 360B may vary along the contour of the frame 26A, 26B.

[0054] like Fig. 10A As shown in , in some embodiments, the brackets 30A, 30B may include shorter upper lips 368A, 368B. In such embodiments, when the suspension material 34A, 34B is subjected to the applied load 364, the suspension material 34A, 34B deflects to the position identified by the dashed line. The deflected suspension material 34A, 34B approaches the support surface 101A, 101B of the frame 26A, 26B, which may expose the user to the hard support surface 101A, 101B of the frame 26A, 26B.

[0055] like Fig. 10B As shown in FIG. 3 , in some embodiments, the brackets 30A, 30B include an elongated upper lip 372A, 372B. When the suspension material 34A, 34B is subjected to an applied load 364, the suspension material 34A, 34B and the elongated upper lip 372A, 372B deflect to the position identified by the dashed line. In this embodiment, the elongated upper lip 372A, 372B provides a resilient cantilever support, and the suspension material 34A, 34B experiences less deflection under the load 364. The user may still be exposed to the hard support surface 101A, 101B of the frame 26A, 26B, but to a lesser extent. Fig. 10A The embodiments shown in the drawings are minimal.

[0056] Fig. 10CAn arrangement is shown in which the bracket 30A, 30B includes an elongated upper lip 372A, 372B and a plurality of ribs 360A, 360B extending from the elongated upper lip 372A, 372B. When the suspension material 34A, 34B is subjected to an applied load 364, the suspension material 34A, 34B, the elongated upper lip 372A, 372B and the ribs 360A, 360B deflect to a position identified by a dashed line. When the load 364 is applied, the ribs 360A, 360B hold a portion of the suspension material 34A, 34B above the tension line 348A, 348B, thereby providing a cushioning effect and preventing a user from contacting the support surface 101A, 101B of the frame 26A, 26B. Thus, the elongated upper lips 372A, 372B and ribs 360A, 360B may be positioned along portions of the frame 26A, 26B that contact a user (eg, along the first lateral frame members 86A, 86B or along the armrest 28B) to help reduce pressure points at the edges of the seat structure 10A, 10B.

[0057] Figures 11A-11B Portions of a frame 378 and a bracket 379 having alternative attachment features are shown. In the illustrated embodiment, a first attachment feature on the frame 378 includes a tooth 104C having a generally rectangular rod 376 and a barbed distal end 380. The width 384 of the rod 376 is constant along the length 388 of the rod 376, while the width 392 of the barbed distal end 381 is wider than the width 384 of the rod 376. A second attachment feature on the bracket 379 includes an aperture 264C having a width 393 sized to receive the rod 376. The depth 394 of each aperture 264C can be generally similar to the length 388 of each rod 376. The barbed distal end 380 can extend into a channel 395 of the bracket 379. The width 392 of each barbed distal end 381 is wider than the width 393 of each aperture 264C. The wider width 392 of the barbed distal end 380 prevents the tooth 104C from being pulled out of the bracket 379 in response to loading of the bracket 379 .

[0058] Figures 12A-12BFrame 396 and bracket 398 are shown with portions of alternative attachment features. In the illustrated embodiment, the first attachment feature on frame 396 includes a first tooth 400 having a first shape and a second tooth 404 having a second shape. The first tooth 400 is shown as being rectangular. The second tooth 404 is shown as having a generally rectangular rod 406 and a barbed distal end 407, similar to the rectangular rod 376 and distal end 380 described above. Each first tooth 404 has a width 411 that is generally the same as the width 409 of the rod 406. Each first tooth 404 also has a length 412. The second attachment feature on bracket 398 includes an aperture 264D that is generally the same as aperture 264C described above. The depth 413 of each aperture 264D is generally the same as the length 412 of each first tooth 400. When the bracket 398 is engaged with the frame 396, the barbed distal ends 407 of the second plurality of teeth 408 extend beyond the depth 413 of the aperture 264D and protrude into the channel 410 of the bracket 398. The first teeth 404 do not extend into the channel 410. Since the width of the barbed distal ends 407 is wider than the width of the aperture 264D, the barbed distal ends 407 prevent the teeth 404 from being pulled out of the bracket 398 in response to loading of the bracket 398.

[0059] Figures 13A-13B Frame 420 and bracket 422 are shown with portions of alternative attachment features. In the illustrated embodiment, the first attachment feature on frame 420 includes relatively widely spaced teeth 104E. In other words, the spacing 424 between teeth 104E is greater than the width 428 of each tooth 104E. The second attachment feature on bracket 422 is aperture 264E. The spacing 432 between apertures 264E corresponds to the spacing 424 between teeth 104E. In the illustrated embodiment, aperture 264E is a cavity. Aperture 264E has a depth 436 less than the width 434 of bracket 422 so that when frame 420 is engaged with bracket 422, teeth 104E are not visible.

[0060] Figures 14A-14C Frame 437 and bracket 438 are shown with portions of alternative attachment features. In the illustrated embodiment, frame 437 includes a plurality of first attachment features, which are apertures 264F. Bracket 438 includes a plurality of second attachment features, which are teeth 104F. The apertures 264F are evenly spaced and have a rectangular cross section. The spacing 440 between the apertures 264F is approximately the same as the width 444 of the apertures 264F. The teeth 104F have a rectangular cross section and have a length 448 that is approximately the same as the depth 452 of the apertures 264F.

[0061] Figures 15A-15CFrame 458 and bracket 459 are shown with portions of alternative attachment features. In the illustrated embodiment, bracket 459 includes a first plurality of teeth 460, a second plurality of teeth 464, and a third plurality of teeth 468. Teeth 460, 464, and 468 have different widths. Each first tooth 460 has a first width 472. Each second tooth 468 has a second width 476 wider than the first width 472. Each third tooth 468 has a third width 480 wider than the second width 476. The first teeth 460, the second teeth 464, and the third teeth 468 can be equally spaced. In the illustrated embodiment, the spacing 484 between teeth 460, 464, 468 is the same as the first width 472. Frame 458 includes a first plurality of orifices 488, a second plurality of orifices 492, and a third plurality of orifices 496. Orifices 488, 492, 496 have different widths. Each first orifice 488 has a first width 500. Each second aperture 496 has a second width 504 that is wider than the first width 500. Each third aperture 496 has a third width 508 that is wider than the second width 504. The first aperture 488, the second aperture 492, and the third aperture 496 are configured to receive the first tooth 460, the second tooth 464, and the third tooth 468, respectively.

[0062] Figures 16A-16B A frame 510 including a curved portion 512 and a bracket 514 including a curved portion 516 are shown. The frame 510 includes a straight portion 559 having a plurality of evenly spaced apertures 264G of equal width. The curved portion 512 of the frame 510 has a single elongated aperture 567. The bracket 516 includes a straight portion 563 having evenly spaced teeth 104G of equal width. The spacing 565 between the apertures 264G is approximately equal to the width 571 of the teeth 104G. The curved portion 516 of the bracket 514 includes a single elongated tooth 584. The single elongated aperture 567 at the curved portion 512 of the frame 510 and the single elongated tooth 584 at the curved portion 516 of the bracket 514 can facilitate the manufacture of the frame 510 and the bracket 514 and the assembly of the seat structures 10A, 10B.

[0063] Fig.17 A seat structure 544 embodying the present invention is shown. The seat structure 544 is shown to be a saddle-shaped stool. The stool includes a base 545, support columns 546, a frame 548, a bracket 552, and a suspension material 556. The frame 548, bracket 552, and suspension material 556 of the seat structure 544 are configured to form a stool having a relatively high and narrow front and a relatively short and wide back.

[0064] like Fig.18B, the frame 548 includes a front portion 560, a first side portion 564, a second side portion 568, and a rear portion 572. The front portion 560 extends in a vertical direction and may be generally arcuate. The front portion 560 is spaced apart from the rear portion 523 and defines an opening 580 therebetween. The first side portion 564 and the second side portion 568 are spaced apart and are generally perpendicular to the front portion 560 and the rear portion 572. In the illustrated embodiment, the front portion 560, the first side portion 564, the second side portion 568, and the rear portion 572 are coupled together to form a closed loop or ring.

[0065] like Figures 18B-18C 560. As shown in FIG. 5 , the rear portion 572 has an extended width 588 that is wider than the width 592 of the front portion 560. The first side portion 564 and the second side portion 568 are shaped so that the width 596 of the opening 580 increases from the front portion 560 to the rear portion 572. The lateral portion 600 is positioned between the first side portion 564 and the second side portion 568. The support column 546 is attached to the lateral portion 600. In the illustrated embodiment, the first side portion 564 and the second side portion 568 have a curved shape. The front portion 560 has a height that is greater than the height of the first side portion 564 and the second side portion 568.

[0066] The frame 548 includes a support surface 604 and an outer perimeter 608. The outer perimeter 608 includes a plurality of first attachment features 610 extending outwardly. In the illustrated embodiment, the first attachment features 610 are teeth 611. In other embodiments, the first attachment features 610 may be apertures. In the illustrated embodiment, some of the first attachment features 610 are integrally formed with the frame 548. Fig.17 In the embodiment shown in , the frame 548 also includes a separate plug-in member 612 having a first attachment feature 610 .

[0067] like Fig.17 , the bracket 552 includes a front portion 616, a first side portion 620, a second side portion 624, and a rear portion 628. The front portion 616 is spaced apart from the rear portion 628. The first side portion 620 and the second side portion 624 are spaced apart along and generally perpendicular to the front portion 616 and the rear portion 628. The front portion 616, the first side portion 620, the second side portion 624, and the rear portion 628 are coupled together to form a continuous loop or ring.

[0068] The bracket 552 includes a support surface 644 and an inner periphery 648. A plurality of second attachment features 650 extend inwardly from the inner periphery 648. In the illustrated embodiment, the second attachment features 650 are apertures 651. In other embodiments, the second attachment features 650 may be teeth. The apertures 651 of the bracket 552 receive the teeth 611 of the frame 548 to connect the bracket 552 to the frame 548.

[0069] The suspension material 556 is coupled to the bracket 552. In the illustrated embodiment, the suspension material 556 is molded into the bracket 552. In alternative embodiments, the suspension material 556 may be attached by the bracket 552 using other suitable coupling means. The suspension material 556 may be made of a woven or knitted material, such as an elastomeric material, a fabric, or a molded polymer material.

[0070] When the bracket 552 is connected to the frame 548 by engaging the first plurality of attachment features 102A, 102B with the second plurality of attachment features 262A, 262B, the suspension material 556 is stretched over the opening 580 of the frame 548. Fig.17 As shown in FIG. 5 , when the bracket 552 is attached to the frame 548, the suspension material 556 forms a saddle shape. The front portion 560 of the frame 548 defines the "saddle angle" portion of the saddle, the rear portion 572 of the frame 548 forms a raised rear support portion, and the two curved side portions 564, 568 are configured to engage the user's thighs. In some embodiments, the bracket 552 may include a plurality of ribs (similar to Fig. 10C 560A, 360B), which are positioned along portions of the bracket 552 that may experience point loading (such as along the first and second side portions 564, 568).

[0071] Figures 19A-19EA mold tool 656 is shown for forming a bracket (such as any of the brackets described above) with an inner molded edge of a hanging material. The mold tool 656 includes a first mold member 660 and a second mold member 664. The first mold member 660 and the second mold member 664 define a cavity 668 therebetween. The hanging material is captured between the first mold member 660 and the second mold member 664 so that the edge of the hanging material is disposed within the cavity 668. In embodiments where the second attachment features 262A, 262B are apertures 264A, 264B, the first mold part 660 includes features 672 (e.g., teeth 672' and protrusions 672") that define the apertures 264A, 264B, channels 304A, 304B, upper surface portions 308A, 308B, and upper lips 280A, 280B of the bracket. In some embodiments, the features 672 are on a removable insert 676 so that the same mold tool 656 can be used to mold different configurations of the brackets 30A, 30B. The second mold part 664 has a wall 680 that abuts an end 684 of the feature 672 of the first mold part 660, thereby forming and defining a through opening or recess in the bracket.

[0072] When forming the brackets 30A, 30B, the edges 356A, 356B of the suspension material 34A, 34B are positioned within the mold 656, such as Fig.19B . The first mold member 660 and the second mold member 664 are closed so that the first mold member 660 and the second mold member 664 are stacked vertically above each other with the edges 356A, 356B positioned therebetween. The liquefied bracket material is introduced into the cavity 668 through the passage 688 defined in the first mold member 660, for example by injection molding. The liquefied bracket material is allowed to harden around the edges 356A, 356B of the suspension material 34A, 34B disposed in the cavity 668 ( Fig.19C After the liquefied bracket material has hardened, the first mold member 660 opens relative to the second mold member 664 in a direction generally perpendicular to the teeth 672 of the first mold member 660 (e.g., in a vertical direction) to hold the brackets 30A, 30B on the first mold member 660 ( Fig.19D ). Applying a force or load to the suspension material 34A, 34B to demold or remove the bracket 30A, 30B from the first mold part 660 ( Fig.19E ).

[0073] Return to see Figures 1A-2BTo attach the bracket 30A, 30B to the frame 26A, 26B, a portion of the second attachment feature 262A, 262B of the bracket 30A, 30B is aligned with a portion of the first attachment feature 102A, 102B of the frame 26A, 26B, for example, by aligning one of the plurality of outwardly extending teeth 104A, 104B with one of the apertures 264A, 264B. Next, the aperture 264A, 264B in the bracket 30A, 30B is pushed along the length 208A, 208B of the tooth 104A, 104B so that the distal end 204A, 204B of the tooth 104A, 104B is disposed between the two posts 314A, 314B and flush along the channel 304A, 304B. The plurality of teeth 104A, 104B are then successively engaged with the plurality of apertures 264A, 264B until all of the teeth 104A, 104B are received in one of the apertures 264A, 264B.

[0074] In embodiments where the apertures 264A, 264B are straight-through openings, this attachment process is fully visible and can be controlled on a tooth-by-tooth basis. Tool 692 (including rollers 696, 700, 704) Fig. 20 ) moves around the periphery of the bracket 30A, 30B to secure the bracket 30A, 30B to the frame 26A, 26B. The rollers 696, 700 of the tool 692 press against the bracket 30A, 30B and roll along its periphery to connect the bracket 30A, 30B to the frame 26A, 26B. The rollers 704 ride within the channel 304A, 304B defined between the upper lip 280A, 280B and the lower lip 286A, 286B of the bracket 30A, 30B, which acts as a track for the tool 692. Once the bracket 30A, 30B is attached to the frame 26A, 26B, the suspension material 34A, 34B is held taut across the opening 98A, 98B defined by the frame 26A, 26B.

[0075] Various features and advantages of the invention are set forth in the following claims.

Claims

1. A seat structure, comprising: a backrest comprising a plurality of frame members including a first frame member and a second frame member, the backrest defining an opening between the plurality of frame members, the first frame member having a boss extending from a first end of the first frame member and a tab movably coupled to the boss, the second frame member having a hole formed in an edge of the second frame member and a recess formed in a surface of the second frame member adjacent to the hole, the hole receiving the boss to align the first frame member with the second frame member, the recess receiving the tab to secure the boss within the hole; a bracket attached to the first frame member and to the second frame member; as well as A hanging material is attached to the bracket and extends over the opening in the backrest.

2. The seat structure according to claim 1, wherein: The tab depends from the boss.

3. The seat structure according to claim 2, wherein: The tab includes an enlarged distal portion received in the recess.

4. The seat structure according to claim 3, wherein: The recess is a through hole formed through an outer surface of the second frame member.

5. The seat structure according to claim 3, wherein: The tab secures the first frame member and the second frame member together without additional fasteners.

6. The seat structure according to claim 3, wherein: The first frame member further includes a second boss extending from a second end of the first frame member opposite to the first end and a second tab movably connected to the second boss, wherein the plurality of frame members further include a third frame member having a hole formed in an edge of the third frame member and a recess formed in a surface of the third frame member adjacent to the hole, wherein the hole of the third frame member receives the second boss to align the first frame member with the third frame member, and wherein the recess of the third frame member receives the second tab to secure the boss within the hole.

7. The seat structure according to claim 3, wherein: When the boss is received in the recess, the outer surface of the first frame member is generally flush and aligned with the outer surface of the second frame member.

8. An armrest for a seat, the armrest comprising: a frame defining an opening and including a plurality of first attachment features formed on an outer perimeter of the frame; a bracket including a plurality of second attachment features formed on an inner periphery of the bracket, the plurality of second attachment features engaging the plurality of first attachment features to attach the bracket to the frame, and A hanging material is attached to the bracket and extends over the opening in the frame.

9. The handrail according to claim 8, wherein: The frame includes an inner portion facing the opening and an outer portion opposite the inner portion and facing away from the opening, and wherein the plurality of first attachment features are arranged along the outer portion.

10. The handrail according to claim 8, wherein: The frame is ring-shaped.

11. The handrail according to claim 8, wherein: The first plurality of attachment features are teeth, and wherein the second plurality of attachment features are apertures.

12. The handrail according to claim 8, wherein: The suspension material is molded into the bracket.

13. The seat structure according to claim 8, wherein: The plurality of first attachment features are positioned on each of the first side frame member, the second side frame member, the first transverse frame member, and the second transverse frame member, and wherein the plurality of second attachment features are positioned on each of the first side bracket member, the second side bracket member, the first transverse bracket member, and the second transverse bracket member.

Images