DYNAMIC MORPHING SUPPORT MECHANISM AND A DEFOLDABLE AND STOOMI-PROOF STRUCTURE CONTAINING THE MECHANISM

Abstract

A support mechanism for a support structure comprises a first and a second chain assembly, as well as support subcomponents connected to the first chain assembly. The links of the first chain assembly have a first projection structure extending inward in one direction. The links of the second chain assembly have a second, inwardly directed projection structure. The projection structures are configured to detachably connect to one another in response to a joint movement of the chain assemblies along a predefined deployment path, and to separate and decouple from one another in response to a joint movement of the chain assemblies along a predefined stowage path.The subcomponents of the support structure work together to form an unfoldable support surface, and the projection structures interlock to be self-supporting when unfolded, so that the unfoldable support surface is load-bearing.

Description

TECHNICAL FIELD

[0001] The subject matter embodiments described herein generally relate to a deployable and stowable support structure employing a dynamic morphing support mechanism. More specifically, embodiments of the subject matter relate to a retractable load-bearing support structure—such as a table, armrest, headrest, door, or wall—suitable for vehicular applications (aircraft, watercraft, automobiles, trains, spacecraft). BACKGROUND

[0002] Extendable, retractable, and stowable components, structures, and support surfaces are often used in areas where space is limited. For example, vehicles such as aircraft may use tables, seat pans, armrests, cup holders, displays, footrests, or doors that can be folded out, extended, or otherwise removed from storage when needed. These and other types of rigid structures or support surfaces can be awkward or difficult to stow when not in use. Furthermore, conventional mechanisms designed to facilitate the deployment and stowage of physical components can be overly complex, noisy, and / or difficult to install and maintain.

[0003] Accordingly, it is desirable to have a support mechanism or subassembly that can be used with a deployable and stowable structure, wherein the structure and its support mechanism can dynamically transition between a rigid, load-bearing state and a compact, stowable, retracted state. Furthermore, other desirable features and characteristics will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. SHORT SUMMARY

[0004] A deformable support mechanism for a load-bearing support structure is disclosed herein. Certain embodiments of the deformable support mechanism include: a first chain assembly, a second chain assembly, and a plurality of subcomponents of a work surface. The first chain assembly has a plurality of first chain links pivotally connected in series, and each of the first chain links includes first outwardly directed structural features and first inwardly directed structural features opposite the first outwardly directed structural features. The second chain assembly has a plurality of second chain links pivotally connected in series, and each of the second chain links includes second inwardly directed structural features.The first and second inwardly facing structural features are configured to be releasably connected to one another in response to joint movement of the first and second track assemblies along a predefined deployment path. The first and second inwardly facing structural features are configured to separate and decouple from one another in response to joint movement of the first and second track assemblies along a predefined stowage path. The work surface subcomponents are each connected to the plurality of first track links, with a deployed number of the work surface subcomponents cooperating to form a deployable work surface. The first and second inwardly facing structural features interlock to be self-supporting when deployed, such that the deployable work surface is load-bearing.

[0005] Certain embodiments of the deformable support mechanism include: a first chain assembly having a plurality of first chain links pivotally connected in series; and a second chain assembly having a plurality of second chain links pivotally connected in series. Each of the first chain links includes: first outwardly directed structural features and first inwardly directed structural features opposite the first outwardly directed structural features. Each of the second chain links includes: second outwardly directed structural features and second inwardly directed structural features opposite the second outwardly directed structural features.The first and second inwardly directed structural features are configured to be releasably coupled to one another in response to joint movement of the first and second track assemblies along a predefined deployment path. The first and second inwardly directed structural features are configured to separate and decouple from one another in response to joint movement of the first and second track assemblies along a predefined stowage path. The first and second inwardly directed structural features interlock to be self-supporting in the deployed state, such that a deployed assembly of the first and second track assemblies is load-bearing.

[0006] Also disclosed herein is a deformable load-bearing support structure. Certain embodiments of the deformable load-bearing support structure include: a plurality of upper assemblies hinged together in series; a plurality of lower assemblies hinged together in series; and a guide rail assembly configured to receive the upper and lower assemblies. Each upper assembly includes: an upper assembly leading edge portion; an upper assembly leading hinge structure located at the upper assembly leading edge portion; an upper assembly trailing edge portion; an upper assembly trailing hinge structure located at the upper assembly trailing edge portion; an outer surface defining a portion of a deployable work surface; and upper assembly structural locking features opposed to the outer surface.The upper assembly front hinge structure is configured to provide a front hinge axis of the upper assembly, the upper assembly rear hinge structure is configured to provide a rear hinge axis of the upper assembly, and the outer surfaces of a deployed number of the plurality of upper assemblies cooperate to form the deployable work surface. Each lower assembly includes: a lower assembly front edge portion; a lower assembly front hinge structure located at the front edge portion of the lower assembly; a lower assembly rear edge portion; a lower assembly rear hinge structure located at the rear edge portion of the lower assembly; and structural locking features of the lower assembly.The front hinge structure of the lower assembly is configured to form a front hinge axis of the lower assembly, and the rear hinge structure of the lower assembly is configured to form a rear hinge axis of the lower assembly. The guide rail assembly allows for sliding movement of the upper and lower assemblies. The structural locking features of the upper assembly and the structural locking features of the lower assembly are configured to be releasably interconnected in response to joint movement of the upper and lower assemblies along a deployment path defined by the guide rail assembly. The upper and lower assemblies are interlocked to be self-supporting when deployed, such that the deployable work surface is load-bearing.The structural locking features of the upper assembly and the structural locking features of the lower assembly are configured to separate and decouple from each other in response to joint movement of the upper and lower assemblies along a stowage path defined by the guide rail assembly.

[0007] Certain embodiments of the deformable support mechanism include: a first chain assembly having a plurality of first chain links pivotally connected in series; a second chain assembly having a plurality of second chain links pivotally connected in series; and a plurality of support subcomponents each connected to the plurality of first chain links. Each of the first chain links includes: a first base having an outwardly facing surface and an inwardly facing surface; and a first protrusion structure extending in a direction away from the inwardly facing surface of the first base, the first protrusion structure having a first irregular side profile shape.Each of the second track links comprises: a second base having an outwardly facing surface and an inwardly facing surface; and a second protrusion structure extending in a direction away from the inwardly facing surface of the second base, the second protrusion structure having a second irregular side profile shape. The first and second protrusion structures are configured to releasably connect to each other in response to collective movement of the first and second track assemblies along a predefined deployment path, and the first and second protrusion structures are configured to separate and decouple from each other in response to collective movement of the first and second track assemblies along a predefined stowage path. A deployed number of subcomponents of the support together form a deployable support surface.The first and second projection structures interlock to be self-supporting in the deployed state, so that the deployable support surface is load-bearing.

[0008] Certain embodiments of the deformable support mechanism include: a first chain assembly having a plurality of first chain links pivotally connected in series; and a second chain assembly having a plurality of second chain links pivotally connected in series. Each of the first chain links includes: a first base having an outwardly facing surface and an inwardly facing surface; and a first protrusion structure extending in a direction away from the inwardly facing surface of the first base, the first protrusion structure having a first irregular side profile shape.Each of the second chain links comprises: a second base having an outwardly facing surface and an inwardly facing surface; and a second protrusion structure extending in a direction away from the inwardly facing surface of the second base, the second protrusion structure having a second irregular side profile shape. The first and second protrusion structures are configured to be releasably coupled together in response to collective movement of the first and second chain assemblies along a predefined deployment path, and the first and second protrusion structures are configured to be separated and decoupled from each other in response to collective movement of the first and second chain assemblies along a predefined stowage path.The first and second projection structures interlock to be self-supporting when deployed, such that a deployed assembly of the first and second track assemblies is load-bearing.

[0009] Certain embodiments of the deformable load-bearing support structure include: a plurality of upper assemblies hinged together in series; a plurality of lower assemblies hinged together in series; and a guide rail assembly configured to receive the upper and lower assemblies. Each upper assembly includes: an upper assembly leading edge portion; an upper assembly leading hinge structure located at the upper assembly leading edge portion; an upper assembly trailing edge portion; an upper assembly trailing hinge structure located at the upper assembly trailing edge portion; and an upper assembly boss structure.The upper assembly front hinge structure is configured to form a top assembly front hinge axis, and the upper assembly rear hinge structure is configured to form a top assembly rear hinge axis. Each bottom assembly includes: a bottom assembly front edge portion; a bottom assembly front hinge structure located at the bottom assembly front edge portion; a bottom assembly rear edge portion; a bottom assembly rear hinge structure located at the bottom assembly rear edge portion; and a bottom assembly boss structure.The front hinge structure of the lower assembly is configured to provide a front hinge pivot axis of the lower assembly, and the rear hinge structure of the lower assembly is configured to provide a rear hinge pivot axis of the lower assembly. The guide rail assembly allows for sliding movement of the upper and lower assemblies. The boss structures of the upper assembly and the boss structures of the lower assembly are configured to be releasably interconnected in response to joint movement of the upper and lower assemblies along a deployment path defined by the guide rail assembly, and the upper and lower assemblies interlock to be self-supporting and load-bearing when deployed.The boss structures of the upper assembly and the boss structures of the lower assembly are configured to separate and decouple from each other in response to joint movement of the upper and lower assemblies along a stowage path defined by the guide rail assembly.

[0010] This summary is intended to introduce, in simplified form, a selection of concepts described further below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be an aid in determining the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A more complete understanding of the subject matter will be obtained from the detailed description and claims when considered in conjunction with the following figures, wherein like reference numerals refer to similar elements in the figures. Fig. 1 is a front perspective view of a load-bearing support structure (e.g., a table) in a retracted and stowed condition according to certain embodiments of the invention; Fig. 2 is a front perspective view of the load-bearing support structure in an extended and deployed state; Fig. 3 is a front perspective view of an exemplary embodiment of a deformable support mechanism suitable for use with the load-bearing support structure, the support mechanism being illustrated in a retracted and stowed condition; Fig. 4 is a rear perspective view of a lower assembly suitable for use with a first embodiment of the invention disclosed herein; Fig. 5 and Fig. 6 are front perspective views of an exemplary embodiment of a lower connection component suitable for use with the Fig. 4 shown lower assembly; Fig. 7 is a side view of the lower connecting component; Fig. 8 is a bottom view of the lower connecting component; Fig. 9 is a perspective view of an exemplary embodiment of a spring assembly suitable for use with the Fig. 4 shown lower assembly; Fig. 10 is a side view of the spring assembly; Fig. 11 is a plan view of the spring assembly; Fig. 12-15 are perspective views showing the assembly steps associated with the manufacture of the Fig. 4 shown lower assembly; Fig. 16 is a rear perspective view of an upper assembly suitable for use with the first embodiment of the invention as disclosed herein; Fig. 17 and Fig. 18 are front perspective views of an exemplary embodiment of an upper connection component suitable for use with the Fig. 16 shown upper assembly; Fig. 19 is a side view of the upper connecting component; Fig. 20 is a plan view of the upper connecting component; Fig. 21-24 are perspective views showing assembly steps related to the manufacture of the Fig. 16 illustrate the upper assembly shown; Fig. 25 is a rear perspective view of a leading edge assembly suitable for use with the first embodiment of the invention as disclosed herein; Fig. 26 is a rear perspective view of an exemplary embodiment of a leading edge connection component suitable for use with the Fig. 25; Fig. 27 is a side view of the leading edge connection component; Fig. 28 is a front perspective view showing two examples of the leading edge connecting component; Fig. 29 and Fig. 30 are perspective views showing the assembly steps related to the manufacture of the Fig. 25; Fig. 31 is a front perspective view of chain assemblies showing how upper connector, lower connector, and leading edge connecting components are coupled together in accordance with exemplary embodiments; Fig. 32 is a rear perspective view of one embodiment of a load-bearing support structure in a stowed condition; Fig. 33 is a rear perspective view of the load-bearing support structure in the deployed state; Fig. 34 is a side view of the load-bearing support structure in the stowed state; Fig. 35 is a front perspective view of an exemplary embodiment of a guide rail suitable for use with the Fig. 32-34 shown load-bearing support structure; Fig. 36 is a side view of the guide rail; Fig. 37 is a front view of a part of the guide rail, seen from the perspective of line AA in Fig. 36; Fig. 38 is a side view showing the manner in which cooperating chain assemblies are installed on the guide rail; Fig. 39-41 are side views of two chain assemblies showing how the chain assemblies mesh during use; Fig. 42 is a front perspective view of one embodiment of a load-bearing support structure with certain components removed to show the interaction between spring assemblies and a guide rail; Fig. 43 is a side view of the Fig. 42 shown supporting structure; Fig. 44 is a rear perspective view of a lower assembly suitable for use with a second embodiment of the invention disclosed herein; Fig. 45 is a top perspective view of an exemplary embodiment of a lower connection component suitable for use with the Fig. 44 shown lower assembly; Fig. 46 is a perspective view of the lower connecting component from below; Fig. 47 is a side view of the lower connecting component; Fig. 48 is a plan view of the lower connecting component; Fig. 49 and Fig. 50 are perspective views showing the assembly steps related to the manufacture of the Fig. 44 shown lower assembly; Fig. 51 is a rear perspective view of an upper assembly suitable for use with the second embodiment of the invention disclosed herein; Fig. 52 is a top perspective view of an exemplary embodiment of an upper connection component suitable for use with the Fig. 51 shown upper assembly; Fig. 53 is a bottom perspective view of the upper connecting component; Fig. 54 is a side view of the upper connecting component; Fig. 55 is a plan view of the upper connecting component; Fig. 56 is an exploded perspective view showing the assembly steps associated with the manufacture of the Fig. 51 shows the upper assembly; Fig. 57 is a rear perspective view of a leading edge assembly suitable for use with the second embodiment of the invention disclosed herein; Fig. 58 is a rear perspective view of an exemplary embodiment of a leading edge connection component suitable for use with the Fig. 57; Fig. 59 is a front perspective view of the leading edge connection component; Fig. 60 is a rear view of the leading edge connection component; Fig. 61 is a bottom view of the leading edge connection component; Fig. 62 is a rear perspective view of an exemplary embodiment of a center leading edge connection component suitable for use with the Fig. 57 shown leading edge assembly; Fig. 63 is a plan view of the center leading edge connection component; Fig. 64 is a perspective front view showing the manufacture of the Fig. 57 shows the leading edge assembly; Fig. 65-70 are perspective views showing manufacturing steps that Fig. 57 shown leading edge assembly; Fig. 71 is a front perspective view of one embodiment of a load-bearing support mechanism in a stowed condition; Fig. 72 is a front perspective view of a portion of the load-bearing support mechanism in an extended condition; Fig. 73 is a perspective view of an exemplary embodiment of a guide rail suitable for use with the Fig. 71 and Fig. 72 shown load-bearing support structure; Fig. 74 is a front view of the guide rail; Fig. 75 is a cross-sectional view of the guide rail, seen from the line BB in Fig. 74; Fig. 76 and Fig. 77 are side views of two chain assemblies showing how the chain assemblies mesh during use; Fig. 78 and Fig. 79 are cross-sectional side views of the two chain assemblies with certain components removed to show the interaction between the chain assemblies and a guide rail. DETAILED DESCRIPTION

[0012] The following detailed description is merely illustrative and is not intended to limit the embodiments of the subject matter or the application and uses of such embodiments. As used herein, the word "exemplary" means "serving as an example, instance, or illustration." Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any express or implied theory presented in the foregoing technical field, background, brief summary, or the following detailed description.

[0013] The following description may refer to elements, components, or features that are "coupled" together. Unless expressly stated otherwise, "coupled" means that one element / node / feature is directly or indirectly connected (or communicates directly or indirectly with) another element / node / feature, and not necessarily mechanically. In addition, certain terms in the following description may be used for reference purposes only and are therefore not to be considered limiting. For example, terms such as "upper," "lower," "top," and "bottom" refer to the referenced directions in the drawings.Terms such as "front," "rear," "back," "side," "outer," and "inner" describe the orientation and / or location of parts of the component within a consistent, but arbitrary, frame of reference, which is made clear by reference to the text and accompanying drawings in which the component in question is described. This terminology may include the words expressly mentioned above, their derivatives, and words of similar import. Likewise, the terms "first," "second," and other numerical terms referring to structures do not imply any order unless clearly indicated by the context.

[0014] The dynamic morphing (shape-changing) support mechanisms and associated physical structures presented herein can be deployed to a stable and load-bearing state and retracted to a compact and stowable state. In accordance with certain embodiments, the disclosed mechanisms and support structures can be used aboard a vehicle, such as an aircraft. The figures depict exemplary embodiments suitable for serving as stowable tables aboard an aircraft. However, it should be appreciated that embodiments of the disclosed subject matter can be used for other vehicular applications, including, but not limited to, trains, helicopters, automobiles, watercraft, monorails, amusement park rides, transportation systems, ski lifts, and the like.Furthermore, embodiments of the disclosed subject matter may also be used for non-vehicle applications, including, but not limited to, residential applications, commercial applications, office applications, tools, manufacturing equipment, recreational equipment, etc. These and other applications, use cases, and platforms are contemplated by this disclosure. For example, the support mechanisms and systems described below may be used in addition to load-bearing surfaces in a vertical or curved assembly, such as in a display mounting application.

[0015] Fig. 1 is a front perspective view of a load-bearing support structure 100 in a retracted and stowed condition, and Fig. Figure 2 is a front perspective view of the load-bearing support structure 100 in an extended and deployed state. The illustrated embodiment of the support structure 100 is configured as a stowable table suitable for aircraft cabin applications. Other platforms, use cases, and configurations for the support structure 100 are also contemplated by this disclosure, and the exemplary table implementation shown in the figures is not intended to be limiting, exhaustive, or restrictive in any way.

[0016] The support structure 100 includes a deformable support mechanism 102 that can be moved between a retracted and stowed state (shown in Fig. 1) and an extended and unfolded state (shown in Fig. 2) can be moved. In the fully retracted and stowed state, the entire support mechanism 102 (or a substantial portion thereof) is located within a correspondingly shaped, sized, and configured storage unit 104 having an internal storage space defined therein. As shown in Fig. 1, a front portion 106 or surface of the support mechanism 102 may protrude from the storage unit 104 when the support mechanism 102 is in the stowed state. The exposed or protruding front portion 106 may be used to facilitate removal and deployment of the support mechanism 102 from the storage unit 104 when needed.

[0017] The illustrated embodiment utilizes a support mechanism 102 that is designed and configured to allow movement along a predefined deployment path to transition from the stowed state to the deployed state. In this regard, the support mechanism 102 can be deployed (extended from an opening 107 defined in the storage unit 104) to create a load-bearing, deployable work surface 108. In this particular example, the deployed portion of the work surface 108 is flat and load-bearing on its two major surfaces (e.g., the top and bottom). The support mechanism 102 is also designed and configured to allow movement along a predefined stowage path to transition from the deployed state to the stowed state.Although not always required, the stowage path for the support mechanism 102 corresponds to the deployment path for the support mechanism 102, with the deployment path and the stowage path being opposite paths.

[0018] In accordance with certain embodiments, the interior of the storage unit 104 is shaped and sized to accommodate the folded storage of at least a portion of the support mechanism 102. In this regard, Fig. 3 is a front perspective view of an exemplary embodiment of the support mechanism 102 suitable for use with the support structure 100. In Fig. 3, the support mechanism 102 is shown in its retracted and stowed state, with at least a portion of the support mechanism 102 folded to save space in the storage unit 104 (in Fig. 3 not shown). As described in more detail below, various embodiments of the support mechanism 102 are configured with a plurality of articulated upper assemblies 114 and a plurality of articulated lower assemblies 116 that, when deployed, fit together and interlock to form a self-supporting, load-bearing component. However, when retracted for storage, the articulated upper and lower assemblies 114, 116 decouple from each other and become independently movable (see Fig. 3, which shows an exemplary folded or packaged assembly of the support mechanism 102. Folded storage of the support mechanism 102 is desirable for applications where storage space is limited or restricted. The illustrated example of the storage unit 104 is suitable for a console or short bulkhead onboard a vehicle, e.g., an aircraft, a piece of furniture, or the like. Other shapes, sizes, form factors, and configurations may also be used. First embodiment

[0019] In the Fig. 4-43 illustrate various structures and features associated with embodiments of a load-bearing support structure having at least one deformable support mechanism with structural features resembling hooks or fingers, the hooks interlocking when the support structure is deployed. Fig. Figure 4 is a rear top perspective view of a lower assembly 202 suitable for use with the disclosed embodiment, and the Fig. 5-15 illustrate various components and subassemblies of the lower assembly 202. As explained in more detail below, embodiments of a load-bearing support structure utilize a plurality of these lower assemblies 202 hinged together in series to form part of the deformable support mechanism.

[0020] In Fig. 4, the directional arrows 204 point in the forward direction, which also corresponds to a deployment direction for the lower assembly 202. The opposite direction of the directional arrows 204 corresponds to a rearward or stowed direction for the lower assembly 202. Accordingly, this description refers to a lower assembly leading edge portion 206 (which generally extends across the width of the lower assembly 202) and a lower assembly trailing edge portion 208 (which also generally extends across the width of the lower assembly 202), where "forward" and "rearward" correspond to the forward / deployment direction indicated by the directional arrows 204. The illustrated embodiment of the lower assembly 202 includes, without limitation: connecting members 210; spring assemblies 212; a lower support bar 214; and end caps 216.These major components of the lower assembly 202 are interconnected by suitable hardware, subcomponents and / or material.

[0021] In this particular embodiment, the connecting components 210 are identical, and a pair of connecting components 210 are arranged to form a chain link. For example, two of the connecting components 210 cooperate to form a lower right chain link 217, and two of the connecting components 210 cooperate to form a lower left chain link 218 (where "left" and "right" refer to the respective sides when the lower assembly 202 is viewed from the front, e.g., directly at the leading edge portion 206). Although in Fig. 4 illustrates an assembly having two lower chain links, alternative embodiments of a lower assembly may also comprise only one lower chain link or more than two lower chain links, depending on the particular application, the intended use of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-bearing capacity.

[0022] As shown and further described below, the connecting components 210 are suitably configured and arranged to form a front hinge structure of the lower assembly and a rear hinge structure of the lower assembly. The front hinge structure is located at or near the leading edge portion 206, and the rear hinge structure is located at or near the trailing edge portion 208. The front hinge structure of the lower assembly 202 is configured to have a front hinge pivot axis 222, and the rear hinge structure of the lower assembly 202 is configured to have a rear hinge pivot axis 224. When multiple lower assemblies 202 are hinged together in series, the hinge structures enable adjacent lower assemblies 202 to rotate relative to one another about the front and rear hinge pivot axes 222, 224.This hinge arrangement facilitates compact (folded or bent) storage of the lower assembly 202, if desired.

[0023] In the Fig. 5-8 show various views of a connecting component 210 (for the lower assembly 202). Fig. 5 is a view from the front right, Fig. 6 is a view from the front left, Fig. 7 is a view from the left side and Fig. Figure 8 is a bottom view. The connecting component 210 may be made of any suitable material with the desired strength and toughness, such as aluminum, nylon, a composite material, plastic, or the like.

[0024] The figures show the structural features that form the front hinge structure 226 and the rear hinge structure 228 of the lower assembly 202. The front and rear hinge structures 226, 228 occupy approximately half the lowermost width of the connecting component 210. This configuration allows multiple connecting components 210 to be connected / articulated in series. The front hinge structure 226 has a hole 230 that serves to receive a hinge pin, rod, bolt, or other suitably configured fastener or connecting element. Similarly, the rear hinge structure 228 has a hole 232 that serves to receive another hinge pin, rod, bolt, fastener, connecting element, or the like.A line passing through the center of the hole 230 corresponds to the front hinge pivot axis 222, and a line passing through the center of the hole 232 corresponds to the rear hinge pivot axis 224 (see . Fig. 7).

[0025] The base of the connecting component 210 includes a slot 234 formed therein. The slot 234 is shaped, sized, and configured to receive a portion of the lower support bar 214 (see Fig. 15). The base of the connecting component 210 may also include any number of threaded holes or inserts 236 for receiving threaded connectors for coupling the lower support bar 214 to the connecting component 210. In certain embodiments, the connecting component 210 includes a number of through holes 238—which may be countersunk on one or both sides—for receiving screws, bolts, or other fasteners for coupling the end caps 216 to the connecting component 210 (see Fig. 12-15). As in Fig. 4, end caps 216 are attached to the two outermost connecting components 210, while the other connecting components 210 do not have end caps 216. In the illustrated embodiment, the end caps 216 are decorative end caps that cooperate to provide an exposed sidewall surface for the lower assembly 202 when it is deployed (see Fig. 2 and Fig. 33-35). For this purpose, the end caps 216 may be made of wood, imitation wood, plastic, metal, or any other desired material, with or without additional decorative treatment, coating, or texture.

[0026] The connecting component 210 includes structural locking features 240 for the lower assembly 202. As explained below, the structural locking features 240 are shaped, sized, arranged, and configured to cooperate with the corresponding structural locking features of a compatible upper assembly. When deployed in an assembled load-bearing support mechanism, the structural locking features 240 are oriented as inwardly facing structural features (opposing certain outwardly facing structural features of the connecting component 210, e.g., the slot 234). According to the illustrated embodiment, the structural locking features 240 include, without limitation: a hook / finger structure 242 terminating with a projection 244 extending in a direction generally corresponding to the forward / deployment direction indicated by the directional arrows 204 in Fig. 4. The top of the hook / finger structure 242 is convex, with a side profile shape that curves upward from the base of the connecting component 210, peaks at a point of maximum height of the connecting component 210, and curves downward until it terminates at the tip of the projection 244 (see Fig. 7). The projection 244 forms an overhanging support that defines a pocket space 246 below the support and above the front hinge structure 226. An important aspect of the connecting component 210 is that the hook / finger structure 242 is radially centered on the front pivot point (the hinge pivot axis 222) of the connecting component 210. Furthermore, the hook / finger structure 242 is slightly narrowed along its leading edge to facilitate proper alignment and engagement with a corresponding connecting element of an upper assembly, as described below.

[0027] Fig. 9-11 are various views of an exemplary embodiment of a spring assembly 212 suitable for use with the lower assembly 202. The Fig. 13-15 show the spring assemblies 212 in an installed state with the respective connecting components 210. As described in more detail below, the spring assemblies 212 are shaped, sized, configured, and positioned to engage at least one guide rail when the lower assembly 202 is installed for use with a load-bearing support structure. In certain embodiments, the spring assembly 212 is constructed of a strong and resilient material, e.g., plastic, nylon, Delrin, aluminum, or the like.

[0028] The illustrated embodiment of the spring assembly 212 includes, without limitation, a sidewall 250 and a leaf spring 252 coupled to or integrated with the sidewall 250. The sidewall 250 is shaped and configured to abut an adjacent connecting component 210. More specifically, the outer surface 254 of the sidewall 250 faces the connecting component 210 when installed, and the inner surface 256 of the sidewall 250 faces another spring assembly 212 when installed (see Fig. 13-15). The side wall 250 includes two mounting holes 258 formed therein—the mounting holes 258 correspond to and are aligned with the holes 230, 232 formed in the hinge structures 226, 228 of the connecting component 210. The side wall 250 has a first recessed portion 260 (on the inside) and a second recessed portion 262 (on the outside). The recessed portions 260, 262 are shaped, sized, configured, and arranged to accommodate the interconnection / hinge connection of multiple spring assemblies 212 in series.

[0029] According to the illustrated embodiment, the leaf spring 252 is coupled to or integrated into an upper portion of the side wall 250. The leaf spring 252 can be realized as a thin plate-like structure with a curved side profile shape (see Fig. 10). In this particular example, the underside of the leaf spring 252 is convex, with a side profile shape that curves downward from the junction of the side wall 250, reaches a point of minimum height at a point between the holes 258 (this point is closer to the second recessed portion 262 than to the first recessed portion 260), and then curves slightly upward until it terminates at its distal edge. The shape, size, and deflection characteristics of the leaf spring 252 are designed such that the leaf spring 252 flexes when it contacts a guide rail, applying a force that retains the connecting component 210 on the guide rail.

[0030] Fig. 12-15 are perspective views showing the assembly steps associated with the manufacture of the lower assembly 202. Fig. Figure 12 shows a first connecting component 210-1 after installation of an internal thread insert 266 in the hole 232 and a second connecting component 210-2 after installation of threaded connectors 268 in the holes 238. Although in the Fig. 12 to 15, a decorative end cap 216 is attached to the side of the second connecting component 210-2 via the threaded connecting elements 268. Fig. Figure 13 shows the desired alignment and orientation of a first spring assembly 212-1 and a second spring assembly 212-2. Note that the leaf springs of the two spring assemblies 212-1, 212-2 are oriented in opposite directions. Furthermore, note that the two spring assemblies 212-1, 212-2 are arranged on the respective inner sides of the connecting components 210-1, 210-2, so that the two leaf springs face each other. Fig. Figure 14 shows the desired orientation and positioning of a hollow roller 270 (the major longitudinal axis of the hollow roller 270 is aligned with the front joint pivot axis 222 defined by the holes 230). A bolt 272 or other type of fastener is shaped and sized to be inserted through the hole 230 of the second connecting component 210-2, the hole 258 of the second spring assembly 212-2, the hollow roller 270, the hole 258 of the first spring assembly 212-1, and the hole 230 of the first connecting component 210-1. Fig. Figure 15 shows an assembled lower chain link 274 including, without limitation, the various components surrounded by the dashed line. Fig. Figure 15 also shows an end portion of the lower support bar 214, which is shaped and dimensioned to fit into the slots 234 of the connecting components 210-1, 210-2. Threaded fasteners 276 can be used to attach the lower support bar 214 to the two connecting components 210-1, 210-2 (see again Fig. 4).

[0031] Although in Fig. 15, the bolt 272 is used to couple another lower chain link 274 in series. When two lower chain links 274 are hinged together, the bolt 272 passes through the front hinge structures 226 of a rear lower chain link 274 and through the rear hinge structures 228 of a front lower chain link 274. The threaded insert 266 of the front lower chain link 274 receives the threaded end of the bolt 272, which is tightened to secure the two lower chain links 274 together while allowing them to rotate about the corresponding hinge pivot axis. The bolt 272 can also be used to connect a final lower chain link 274 to a leading edge connector (as described below with reference to Fig. 32).

[0032] Fig. 16-24 relate to an exemplary embodiment of an upper assembly 302 suitable for use with the disclosed embodiment.

[0033] Fig. 16 is a rear perspective view of the upper assembly 302, and the Fig. 17-24 illustrate various components and subassemblies of the upper assembly 302. As explained in more detail below, embodiments of a load-bearing support structure utilize a plurality of these upper assemblies 302 hinged together in series to form part of the deformable support mechanism. Some of the structures, features, and functional characteristics of the upper assembly 302 are similar, identical, or equivalent to those described above for the lower assembly 202. For simplicity and brevity, such similar, identical, or equivalent aspects will not be redundantly described in detail herein in connection with the upper assembly 302.

[0034] In Fig. 16, the directional arrow 304 points in the forward direction, which also corresponds to a deployment direction for the upper assembly 302. The opposite direction of the directional arrow 304 corresponds to a rearward or stowage direction for the upper assembly 302. Accordingly, this description refers to a leading edge portion 306 and a trailing edge portion 308 of the upper assembly. The illustrated embodiment of the upper assembly 302 includes, without limitation: connecting components 310; spring assemblies 312 (in Fig. 16 is substantially invisible); and an outer surface 314 defining a portion of a deployable work surface. These major components of the upper assembly 302 are interconnected by suitable hardware, subcomponents, and / or material.

[0035] In this particular embodiment, the connecting components 310 are identical, and a pair of connecting components 310 are arranged to form a chain link. Although in Fig. 16 illustrates an assembly having two upper links (on the left and right sides of the upper assembly 302), alternative embodiments of an upper assembly may include only one upper link or more than two upper links, depending on the particular application, the intended application of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-bearing capacity.

[0036] As shown and further described below, the connecting components 310 are suitably configured and arranged to form a front hinge structure of the upper assembly and a rear hinge structure of the upper assembly. The front hinge structure is located at or near the leading edge portion 306, and the rear hinge structure is located at or near the trailing edge portion 308. The front hinge structure of the upper assembly 302 is configured to form a front hinge pivot axis 322, and the rear hinge structure of the upper assembly 302 is configured to form a rear hinge pivot axis 324. When multiple upper assemblies 302 are hinged together in series, the hinge structures enable adjacent upper assemblies 302 to rotate relative to one another about the front and rear hinge pivot axes 322, 324.This hinge arrangement facilitates compact (folded or bent) storage of the upper assembly 302, if desired.

[0037] In the Fig. 17-20 show various views of a connecting component 310 (for the upper assembly 302). Fig. 17 is a view from the front right, Fig. 18 is a view from the front left, Fig. 19 is a view from the left side and Fig. Figure 20 is a top view. The figures illustrate the structural features that form the front hinge structure 326 and the rear hinge structure 328 of the upper assembly 302. The front and rear hinge structures 326, 328 occupy approximately half the width of the connecting component 310, allowing the interconnection / hinge connection of multiple connecting components 310 in series. The front hinge structure 326 includes a hole 330 formed therein for receiving a hinge pin, rod, bolt, or other suitably configured fastener or connecting element. Similarly, the rear hinge structure 328 includes a hole 332 formed therein for receiving another hinge pin, rod, bolt, fastener, connecting element, or the like.A line passing through the center of the hole 330 corresponds to the front hinge pivot axis 322, and a line passing through the center of the hole 332 corresponds to the rear hinge pivot axis 324 (see . Fig. 19).

[0038] The upper portion of the connecting component 310 includes a slot 334 formed therein (which may be chamfered as shown). The slot 334 is shaped, sized, and configured to receive a portion of a work surface subcomponent 336 that includes, supports, or defines the outer surface 314. (See Fig. 23 and Fig. 24). The upper portion of the connecting component 310 may also include at least one threaded hole or insert 337 (which may be countersunk) for receiving threaded connectors for securing the work surface subcomponent 336 to the connecting component 310. As shown in Fig. 16, the two outermost connecting components 310 receive the fasteners used to hold the work surface subcomponent 336 in position after it has been installed in the slots 334. Although not used in the illustrated embodiment, the connecting component 310 may be suitably configured to receive a decorative end cap (in the manner described above with reference to the end caps 216 for the lower assembly 202).

[0039] The connecting component 310 includes structural locking features 340 for the upper assembly 302. In particular, the structural locking features 340 are shaped, sized, arranged, and configured to cooperate with the corresponding structural locking features 240 of a connecting component 210 of the lower assembly 202. When deployed in an assembled load-bearing support mechanism, the structural locking features 340 are oriented as inward-facing structural features (opposing certain outward-facing structural features of the connecting component 310, e.g., the slot 334). According to the illustrated embodiment, the structural locking features 340 include, among other things: a hook / finger structure 342 terminating with a protrusion 344 extending in a direction generally corresponding to the rearward / stow direction.The hook / finger structure 342 has a side profile shape that begins at or near the front hinge structure 326 with a straight, angled leading edge that slopes rearward, curves rearward and downward until it reaches a lowest point of the connecting component 310, and curves rearward and upward until it ends at the tip of the projection 344 (see . Fig. 19). The projection 344 forms an overhanging support that defines a pocket space 346 above the support and below the upper portion of the connecting component 310.

[0040] Fig. 21-24 are perspective views showing the assembly steps associated with the manufacture of the upper assembly 302. Fig. Figure 21 shows a first connecting component 310-1 after installation of an internally threaded insert 366 into the hole 332, a second connecting component 310-2 and spring assemblies 212 (as described with reference to Fig. 9-11) before assembly. Fig. Figure 22 shows the desired orientation and positioning of a hollow roller 370 (the main longitudinal axis of the hollow roller 370 is aligned with the front joint pivot axis 322 defined by the holes 330). A bolt 372 or other type of fastener is shaped and sized to be inserted through the hole 330 of the second connecting component 310-2, the hole 258 of a spring assembly 212, the hollow roller 370, the hole 258 of another spring assembly 212, and the hole 330 of the first connecting component 310-1. Fig. 22-24, an assembled upper chain link 374 is shown, which includes the two interconnected connecting components 310-1, 310-2.

[0041] Fig. Figure 23 shows an end portion of the work surface subcomponent 336 shaped and sized to fit within the slots 334 of the connecting components 310-1, 310-2. In accordance with certain embodiments, the work surface subcomponent 336 includes a sipe 376 having an inner side 378 and an outer side 380 opposite the inner side 378. The inner side 378 includes sipe coupling features 382 configured to mate and couple with certain outwardly facing structural features of the lower chain link 374, such as the slot 334. In the illustrated embodiment, the sipe coupling features 382 include a protruding portion of the sipe 376 having a side profile shape that conforms to the side profile shape of the slot 334. This allows the slat 376 to be inserted into the slots 334 of the connecting elements 310 (see Fig. 24). The outer surface 380 of the slat 376 defines a portion of a deployable work surface of the load-bearing support structure such that the outer surfaces 380 of a deployed number of slats 376 cooperate to form the deployed work surface. In accordance with certain embodiments, the slat 376 includes a layer of decorative material (e.g., a wood veneer, a patterned laminate material, a painted or treated layer of plastic, metal, or vinyl, or the like) that defines the outer surface 380. In other embodiments, the slat 376 may be fabricated from a single piece of material, e.g., aluminum, having a decorative treatment or coating on its outer surface 380. Threaded fasteners 383 may be used to attach or secure the work surface subcomponent 336 to a series of interconnecting components 310 (see Fig. 16 and Fig. 24).

[0042] Although in Fig. 24, the bolt 372 is used to couple another upper chain link 374 in series. When two upper chain links 374 are hinged together, the bolt 372 passes through the front hinge structures 326 of a rear upper chain link 374 and through the rear hinge structures 328 of a front upper chain link 374. The threaded insert 366 of the front lower chain link 374 receives the threaded end of the bolt 372, which is tightened to secure the two upper chain links 374 together while allowing them to rotate about the corresponding hinge pivot axis. A bolt 372 can also be used to connect a final upper chain link 374 to a front edge link (as described below with reference to Fig. 32).

[0043] Fig. 25-31 show an exemplary embodiment of a leading edge assembly 402 suitable for use with the disclosed embodiment. Fig. 25 is a rear perspective view of the leading edge assembly 402 from above, and in the Fig. 26-30 show various components and subassemblies of the leading edge assembly 402. Fig. 31 is a top perspective view of the front of track assemblies, showing how the components of the upper links, lower links, and leading edge links are interconnected in accordance with exemplary embodiments. Some of the structures, features, and functional characteristics of the leading edge assembly 402 are similar, identical, or equivalent to those described above for the lower assembly 202 and / or the upper assembly 302. For simplicity and brevity, such similar, identical, or equivalent aspects will not be redundantly described in detail herein in connection with the leading edge assembly 402.

[0044] In Fig. 25, the directional arrow 404 points in the forward direction, which also corresponds to a deployment direction for the leading edge assembly 402. The opposite direction of the directional arrow 404 corresponds to a rearward or stowage direction for the leading edge assembly 402. The illustrated embodiment of the leading edge assembly 402 includes, without limitation: leading edge connection components 410; a mounting bracket assembly 412; and at least one trim component 414 that includes or is made of decorative material. These major components of the leading edge assembly 402 are interconnected by suitable hardware, subcomponents, and / or material.

[0045] In this particular embodiment, the connecting components 410 are identical, and a pair of connecting components 410 are arranged to form a leading edge member 415 (see Fig. 31). Although in Fig. 25 illustrates an assembly having two leading edge members (on the left and right sides of the leading edge assembly 402), alternative embodiments of a leading edge assembly may include only one leading edge member or more than two leading edge members, depending on the particular application, the intended application of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-bearing capacity.

[0046] As explained below with reference to Fig. 31 and described in more detail, the connecting components 410 are suitably configured and arranged to form an upper hinge structure and a lower hinge structure for the leading edge assembly 402. The upper hinge structure is arranged and configured to be compatible with the connecting components 310 of an upper assembly 302, and the lower hinge structure is arranged and configured to be compatible with the connecting components 410 of a lower assembly 202. These hinge structures facilitate rotation of the respective upper and lower assemblies 302, 202 about the respective rotational axes defined by the hinge structures.

[0047] In the Fig. 26-28 show various views of a connecting component 410 (for the leading edge assembly 402). Fig. 26 is a right rear view, Fig. 27 is a right side view and Fig. Figure 28 is a left front view showing two connecting components 410 side by side. The figures illustrate the structural features that form the upper hinge structure 416 and the lower hinge structure 418 of the leading edge assembly 402. The upper and lower hinge structures 416, 418 occupy approximately half the width of the connecting component 410, which enables the connection / hinge of a lower connecting component 210 and an upper connecting component 310. The upper hinge structure 416 includes a hole 422 formed therein for receiving a hinge pin, rod, bolt, or other suitably configured fastener or connecting element. Similarly, the lower hinge structure 418 includes a hole 424 formed therein for receiving another hinge pin, rod, bolt, fastener, connecting component, or the like.A line passing through the center of the hole 422 corresponds to an upper hinge pivot axis 426, and a line passing through the center of the hole 424 corresponds to a lower hinge pivot axis 428 (see . Fig. 27).

[0048] The upper and / or front portions of the connecting component 410 may include any number of threaded holes 432 or threaded inserts to facilitate attachment to the mounting bracket assembly 412. Although not used in the illustrated embodiment, the sides of the connecting component 410 may be suitably configured to receive a decorative end cap (in the manner described above with reference to the end caps 216 for the lower assembly 202). As shown in Fig. 28, one of the two connecting components 410 includes threaded inserts 434 installed in the holes 422, 424.

[0049] With further reference to Fig. 31, the connecting component 410 includes structural locking features 440 for the leading edge assembly 402. In particular, the structural locking features 440 are shaped, sized, arranged, and configured to cooperate with the structural locking features 240 of a connecting component 210 of the lower assembly 202 and / or with the structural locking features 340 of a connecting component 310 of the upper assembly 302. When deployed in an assembled load-bearing support mechanism, the structural locking features 440 are oriented as rearward-facing structural features. In accordance with the illustrated embodiment, the structural locking features 440 include, among other things, a protrusion 444 that extends slightly upwardly. As shown in the Fig. As shown in Figures 26-28, the protrusion 444 is located between the upper and lower hinge structures 416, 418. The protrusion 444 forms a support that defines a pocket space 446 above the support and below the upper portion of the connecting component 410. The pocket space 446 is shaped, sized, and configured to receive the protrusion 244 of a lower connecting element 210.

[0050] Fig. 29 and Fig. 30 are perspective views showing the assembly steps associated with the manufacture of the leading edge assembly 402. Fig. Figure 29 shows four of the connecting elements 410 connected to the bracket assembly 412 (e.g., with screws or bolts used in Fig. 29 are not visible). Fig. 29 shows a front fairing component 414-1 prior to attachment to the mounting bracket assembly 412, and Fig. 30 shows the front fairing component 414-1 after attachment via the threaded connectors 450. Fig. 30 also includes an upper fairing component 414-2, which is shown prior to attachment to the top of the bracket assembly 412. In certain embodiments, the upper fairing component 414-2 is attached to the mounting bracket assembly 412 with a suitable adhesive or bonding material. The finished leading edge assembly 402 is shown in Fig. 25. The leading edge assembly 402 is connected to the last instance of a lower assembly 202 and to the last instance of an upper assembly 302 via the various connecting components 210, 310, 410, as shown in Fig. 31 shown.

[0051] The Fig. 32 to 34 show an exemplary embodiment of a load-bearing support structure 500 with a deformable support mechanism 502 that utilizes a plurality of the lower assemblies 202, a plurality of the upper assemblies 302, and the leading edge assembly 402. For simplicity and to facilitate description, the support structure 500 is depicted without a surrounding structure or associated storage unit. Furthermore, the retracted and stowed orientation of the morphable support mechanism 502 is different from that shown in FIGS. Fig. 1-3 shown implementation simplified.

[0052] The support structure 500 includes a plurality of upper assemblies 302 hinged together in series such that the leading edge portion 306 of a rear portion of an upper assembly 302 is connected to the trailing edge portion 308 of a front portion of an upper assembly 302. As explained above, the upper assemblies 302 are connected to each other via the front and rear hinge structures 326, 328 and the pins 372. In this context, the front hinge structures 326 are located on the leading edge portions 306 of the upper assembly, and the rear hinge structures 328 are located on the trailing edge portions 308 of the upper assembly.Similarly, the support structure 500 includes a plurality of lower assemblies 202 hinged together in series such that the leading edge portion 206 of a rear portion of a lower assembly 202 is connected to the trailing edge portion 208 of a forward portion of a lower assembly 202. As explained above, the lower assemblies 202 are connected to each other via the front and rear hinge structures 226, 228 and the pins 272. The front hinge structures 226 are located on the leading edge portions 206 of the lower assembly, and the rear hinge structures 228 are located on the trailing edge portions 208 of the lower assembly.

[0053] As in the Fig. 39, Fig. 40 and Fig. 43, the connected assembly of upper assemblies 302 terminates with a final upper assembly 302-1, and the connected assembly of lower assemblies 202 terminates with a final lower assembly 202-1. The end assemblies 202-1, 302-1 are connected to the leading edge assembly 402 via their respective end chain links 274, 374. More specifically, the connecting components 210 of the final lower assembly 202-1 and the connecting components 310 of the final upper assembly 302-1 are coupled to the connecting components 410 of the leading edge assembly 402, with two connecting components 410 cooperating to form a leading edge link of the leading edge assembly 402 (see Fig. 31 and the corresponding description above).

[0054] When assembled and deployed as described herein, the lower link components 210 and the upper link components 310 are configured to function as chain links hinged together in series. The illustrated embodiment includes two upper chain assemblies (left and right sides) formed by the upper link components 310 and two lower chain assemblies (left and right sides) formed by the lower link components 210. Each upper chain link, implemented with two upper link components 310, includes outwardly directed structural features and inwardly directed structural features opposite the outwardly directed structural features.Likewise, each lower chain link realized with two lower connecting components 310 has outward-facing structural features and inward-facing structural features opposite its outward-facing structural features.

[0055] The inwardly facing structural features of the upper link components 310 (e.g., the hook / finger structures 342) and the inwardly facing structural features of the lower link components 210 (e.g., the hook / finger structures 242) are configured to releasably interconnect in response to joint movement of the upper and lower chain assemblies along a predefined deployment path. Conversely, the inwardly facing structural features of the upper link components 310 (e.g., the hook / finger structures 342) and the inwardly facing structural features of the lower link components 210 (e.g., the hook / finger structures 242) are configured to separate and decouple in response to joint movement of the upper and lower chain assemblies along a predefined stowage path.

[0056] The outwardly directed structural features of the upper connecting components 310 (e.g., the slots 334) can be used to connect the subcomponents of the working surface 336 to the upper chain links. As shown in Fig. 33, an extended number of the work surface subcomponents 336 cooperate to form an extendable work surface 504 of the support structure 500. When the upper and lower track assemblies are deployed and coupled together as described herein, the corresponding hook / finger structures 242, 342 interlock and are self-supporting. As a result, the deployable work surface 504 is load-bearing in the deployed position. In accordance with the illustrated embodiment, the extended portion of the support structure 500 accommodates the load of the work surface 504 and the load of the structure below / opposite the work surface 504.

[0057] The Fig. 39-41 show how the upper and lower connection components 310, 210 cooperate with each other to transition from an uncoupled and separated state to a coupled and locked state. For clarity and simplicity, Fig. 39-41 some components that appear in other figures are not shown. Fig. 39-41 agree with the Fig. 32-34 shown orientation of the support structure 500. In this respect, Fig. 39 a side view corresponding to a first position, Fig. 40 is a side view corresponding to a second position, and Fig. 41 is a side view corresponding to a third position. The first position may represent an initial state before deployment of the morphable support mechanism, the second position may represent an intermediate state (after deployment has begun), and the third position may represent a final deployed position.

[0058] In the Fig. 39 and Fig. 40, the hook / finger structure of the leftmost connecting component 210 and the projection of the leading edge connecting component 410 are fully coupled and interlocked. In particular, the shape of the hook / finger structure precisely matches the shape of the pocket space defined in the leading edge connecting component 410, such that the hook / finger structure occupies most, if not all, of the pocket space. This tight fit is desirable to hold the final lower assembly 202-1 in place and prevent rotation of the final lower assembly 202-1 about its front hinge pivot axis. Fig. 39, the hook / finger structure of the left upper connecting component 310 has not yet fully engaged the hook / finger structure of the paired lower connecting component 210, and a certain gap is visible near the respective projections. In Fig. 40, however, little to no space is visible between these protrusions (which extend in opposite directions when deployed as shown). To this end, the shape of the hook / finger structure of the lower connecting component 210 closely matches the shape of the pocket space defined in the corresponding upper connecting component 310, such that the hook / finger structure occupies most, if not all, of the pocket space. Similarly, the shape of the hook / finger structure of the upper connecting component 310 closely matches the shape of the pocket space defined in the corresponding lower connecting component 210, such that the hook / finger structure occupies most, if not all, of the pocket space.Consequently, when a pair of upper and lower connecting components 310, 210 are fully engaged and locked in this manner, the cooperating structures prevent rotation of the associated upper and lower assemblies 302, 202.

[0059] The sequence of Fig. 39-42 demonstrate how the inward-facing features of the upper and lower assemblies 302, 202 dynamically interact and interlock in response to concerted movement of the upper and lower assemblies 302, 202 along a predefined deployment path. The reverse sequence of Fig. 42-39 illustrate how the inwardly facing features of the upper and lower assemblies 302, 202 dynamically interact and engage in response to the joint movement of the upper and lower assemblies 302, 202 along a predefined stowage path. In this particular embodiment, the deployment and stowage paths follow a common path, but in opposite directions. As shown in the Fig. 39-41, movement of the upper and lower assemblies 302, 202 along the deployment path causes them to approach each other and pivot the lower interconnecting members 210 until the hook / finger structures of the lower interconnecting members 210 engage their corresponding hook / finger structures of the upper interconnecting members 310 and ultimately interlock. The locking prevents rotation of the individual interconnecting components, forming a rigid, interconnected structure from the upper and lower assemblies 302, 202. The offset position of the joints (the hinge axes) in the opposing assemblies 302, 202 prevents vertical movement. As a result, the interlocking assemblies 302, 202 are rigid in all directions: up, down, and side to side.

[0060] With reference to the Fig. 32-38, 42, and 43, the support structure 500 includes a guide rail assembly 508 having at least one guide rail 510. The illustrated embodiment includes two guide rails 510—one for the left-side track assemblies and one for the right-side track assemblies. The guide rail assembly 508 is suitably configured to receive the upper and lower assemblies 302, 202 and is adapted to allow sliding movement of the upper and lower assemblies 302, 202 as required for deployment and stowage of the morphable support mechanism 502. More specifically, each guide rail 510 is configured to receive an upper track assembly (formed from the upper link components 310) and a lower track assembly (formed from the lower link components 210), and each guide rail 510 allows sliding movement of the track assemblies as needed.For this purpose, each guide rail 510 is shaped, sized, and arranged in a desired manner to define and provide the predefined deployment and stowage paths for the upper and lower assemblies 302, 202.

[0061] Each guide rail 510 is also shaped, sized, arranged, and configured to transition the inwardly facing structural features of the upper chain links (e.g., the projections 344) and the lower chain links (e.g., the projections 244) from an uncoupled state to a coupled state in response to concerted movement of the chain assemblies along the deployment path defined by the guide rail 510. Likewise, each guide rail 510 is shaped, sized, arranged, and configured to transition the inwardly facing structural features of the upper chain links (e.g., the projections 344) and the lower chain links (e.g., the projections 244) from the coupled state to the uncoupled state in response to concerted movement of the chain assemblies along the accumulation path defined by the guide rail 510. Fig. 39-41 show the coupling / decoupling processes that result from such concerted movements.

[0062] With reference to the Fig. 35-38, 42, and 43, each guide rail 510 of the illustrated support structure 500 includes various structural features that support and guide the lower and upper assemblies 202, 302 as they move along the guide rail 510. Depending on the embodiment, the guide rail 510 may include, without limitation and in any combination, any of the following structural features: one or more channels, one or more flanges, one or more rails, one or more tracks, one or more tunnels, one or more slots, one or more keys / wedges, one or more projections, one or more ribs, one or more grooves, or the like.

[0063] Although not always required, the illustrated embodiment of the guide rail 510 has a shape similar to an I-beam when viewed in cross-section along a line or plane perpendicular to the major longitudinal axis of the guide rail 510. Fig. 37 shows the shape of the I-beam 514, seen from the line AA in Fig. 36. The I-beam shape 514 is generally characterized by an upper flange 516, a lower flange 518 opposite the upper flange 516, and a web 520 between the upper and lower flanges 516, 518. Although the web 520 is hollow in the illustrated embodiment, it may be a solid web in other embodiments. The flanges 516, 518 and the web 520 cooperate to form a right open channel 522 and a left open channel 524. The web 520 separates the two channels 522, 524 such that the channel 522 is open to the right side of the guide rail 510 and the channel 524 is open to the left side of the guide rail 510. The guide rail 510 has a major longitudinal axis 526 generally defined by a line centered in the track 520 that follows the path defined by the track 520 (see Fig. 35, which shows the entry and exit of the longitudinal axis 526 from the guide rail 510). In certain exemplary embodiments, the guide rail 510 has a curved main longitudinal axis 526, which enables folded storage of the first and second chain assemblies when decoupled from each other, and therefore folded storage of the corresponding lower and upper assemblies 202, 302. The Fig. However, the guide rail 510 shown in Figures 32-38 supports most of the lower and upper assemblies 202, 302 in a straight and unfolded state (except for the portions located in the curved neck area of ​​the guide rail 510). For comparison, the guide rails shown in Fig. 3 are curved to allow the curved and folded configuration when stowed.

[0064] Fig. Figure 38 shows how the lower and upper assemblies 202, 302 (coupled together) are inserted into a guide rail 510. The coupled assemblies 202, 302 can be aligned with the guide rail 510 and laterally (in Fig. 38 to the right) to engage the end of the guide rail 510. The assemblies 202, 302 can be installed on the guide rail 510 and inserted into the Fig. 34. As already explained, the movement of the assemblies 202, 302 in the stowage direction leads to a decoupling of the assemblies 202, 302.

[0065] Fig. 42 and Fig. 43 illustrate the manner in which the spring assemblies 212, 312 engage features of the guide rail 510. As explained above, each lower chain link of the lower assembly 202 includes two spring assemblies 212 (each spring assembly 212 has a leaf spring 252). Similarly, each upper chain link of the upper assembly 302 includes two spring assemblies 312 (each spring assembly 312 also has a corresponding leaf spring). The spring assemblies 212 engage at least the lower flange 518 of the guide rail 510 to maintain the retracted portion of the lower assembly 202 and its lower chain assembly on the guide rail 510 in a stowed state. Likewise, the spring assemblies 312 engage at least the upper flange 516 of the guide rail 510 to maintain the retracted portion of the upper assembly 302 and its upper chain assembly on the guide rail 510 in the retracted state. See also Fig. 14: The undersides of the spring assemblies 212 engage and slide over the surface of the lower flange 518, which defines the channel 522, 524, while the hollow roller 270 engages and rolls over the outwardly facing surface of the lower flange 518. The two opposing spring assemblies 212 flank the web 520 when it is installed on the guide rail 510 (the web 520 would be in the Fig. 14 between the spring assemblies 212-1, 212-2). The spring tension exerted by the leaf springs 252 "clamps" the lower flange 518 between the spring assemblies 212 and the hollow rollers 270. In the upper assembly 302, the spring assemblies 312 ensure that the upper flange 516 of the guide rail 510 is "clamped" between the spring assemblies 312 and the hollow rollers 370.

[0066] The guide rail 510 includes a curved neck portion 530 (see Fig. 38) that serves as a transition for coupling / uncoupling the lower and upper assemblies 202, 302. In the illustrated embodiment, a first end 532 of the curved neck portion 530 is connected to a relatively wide gap between the upper and lower flanges 516, 518 of the guide rail, and a second end 534 of the curved neck portion 530 is connected to a relatively narrow gap between the upper and lower flanges 516, 518. The wide gap keeps the lower and upper assemblies 202, 302 decoupled and spaced apart from each other, and the narrow gap brings the lower and upper assemblies 202, 302 together in the coupled state. The curved neck portion 530 allows the lower and upper assemblies 202, 302 to transition from the uncoupled state to the coupled state (and vice versa) in response to concerted movement during deployment and stowage, as described above with reference to Fig. 39-41. The shape of the curved neck portion 530 and the variable spacing between the upper and lower flanges 516, 518 urge the lower and upper assemblies 202, 302 into the desired positions when moved together during extension and retraction. During movement in the deployment direction, the lower assembly 202 moves closer to the upper assembly 302, and the hook / finger structures 242 of the lower assembly 202 pivot to enter the pocket spaces 346 of the upper assembly 302 and eventually fully engage the hook / finger structures 342 of the upper assembly 302. When the lower assembly 202 is moved in the stowage direction, it moves away from the upper assembly 302, and the hook / finger structures 242 of the lower assembly 202 naturally pivot and detach from the hook / finger structures 342 of the upper assembly 302 and "fall away." See again the Fig. 39-41, which illustrate this process.

[0067] When the support mechanism 502 is extended, some of the connecting elements 210, 310 remain uncoupled (supported by the guide rail assembly 508), and one or more pairs of connecting components 210, 310 may be in a partially coupled state. When the upper and lower assemblies 302, 202 are uncoupled, they are constrained to the path defined by the guide rail 510. The extended portion of the guide rail 510, which includes a portion of the coupled assemblies 302, 202, transmits torque to the guide rail 510. The design of the system ensures the transmission of forces through the upper and lower assemblies 302, 202 to the guide rail 510, which holds the extended portion of the support mechanism 502 in position.

[0068] Although not implemented in the illustrated embodiment, the load-bearing support structure 500 may include a suitably configured storage unit that fully or partially surrounds the guide rails 510. The storage unit may be shaped and sized to allow for the stowage of the morphable support mechanism 502 (including the track assemblies, the upper and lower assemblies 302, 202, etc.) in the stowed state. Furthermore, the storage unit may have an opening defined or formed therein, the opening shaped and sized to allow the passage of the morphable support mechanism 502 when the upper and lower assemblies 302, 202 are connected in the deployed state. See, for example, the Fig. 1 and Fig. 2 shown embodiment. Second embodiment

[0069] Fig. 44-79 illustrate various structures and features relating to embodiments of a load-bearing support structure having at least one deformable support mechanism with structural features resembling a truss architecture, wherein elements of the truss architecture interlock when the support structure is deployed. Many aspects of the first and second embodiments are the same. Indeed, some of the structures, features, and functional properties of the second embodiment of the support structure are similar, identical, or equivalent to those described above for the first embodiment of the support structure. For simplicity and brevity, such similar, identical, or equivalent aspects will not be redundantly described in detail herein in connection with the second embodiment.

[0070] Fig. Figure 44 is a top perspective view of the rear of a lower assembly 602 suitable for use with the disclosed embodiment, and in the Fig. 45-50 illustrate various components and subassemblies of the lower assembly 602. As explained in more detail below, embodiments of a load-bearing support structure utilize a plurality of these lower assemblies 602 hinged together in series to form part of the deformable support mechanism. The illustrated embodiment of the lower assembly 602 includes, without limitation, connecting components 610; lower support bars 614; and end caps 616. These major components of the lower assembly 602 are interconnected by suitable hardware, subcomponents, and / or material.

[0071] In this particular embodiment, the connecting components 610 are identical, and the lower assembly 602 includes three of them (one at or near the left side, one at or near the right side, and one between the left and right sides). Although in Fig. 44 illustrates an assembly having three interconnection components 610, alternative embodiments of a lower assembly may include only one lower interconnection element or more than three lower interconnection elements, depending on the particular application, the intended use of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-bearing capacity.

[0072] As shown and further described below, the connecting components 610 are configured and arranged to form a front hinge structure of the lower assembly and a rear hinge structure of the lower assembly. The front hinge structure is located at or near the front edge portion of the lower assembly 602, and the rear hinge structure is located at or near the rear edge portion of the lower assembly 602. The front hinge structure of the lower assembly 602 is configured to have a front hinge pivot axis, and the rear hinge structure of the lower assembly 602 is configured to have a rear hinge pivot axis. When multiple lower assemblies 602 are hinged together in series, the hinge structures enable adjacent lower assemblies 602 to rotate relative to one another about the front and rear hinge pivot axes.This hinge arrangement facilitates compact (folded or bent) storage of the lower assembly 602, if desired.

[0073] Fig. 45-48 show various views of a connecting component 610 (for the lower assembly 602). Fig. 45 is a perspective top view, Fig. 46 is a perspective bottom view, Fig. 47 is a side view and Fig. 48 is a top view. The connecting component 610 may be made of any suitable material with the desired strength and toughness, such as aluminum, nylon, a composite material, plastic, or the like.

[0074] The figures illustrate the structural features that comprise the front hinge structure 626 and the rear hinge structure 628 of the lower assembly 602. The front and rear hinge structures 626, 628 are offset relative to one another. This offset configuration allows for the connection / anchoring of multiple connecting components 610 in series. The front hinge structure 626 includes a hole 630 designed to receive a hinge pin, rod, bolt, or other suitably configured fastener or connecting element. Similarly, the rear hinge structure 628 includes a hole 632 formed therein for receiving another hinge pin, rod, bolt, fastener, connecting element, or the like.A line passing through the center of hole 630 corresponds to the rotation axis of the front hinge, and a line passing through the center of hole 632 corresponds to the rotation axis of the rear hinge.

[0075] The base of the connecting component 610 includes slots 634 formed therein. At least one slot 634 is shaped, sized, and configured to receive a portion of a lower support bar 614, and at least one slot 634 is shaped, sized, and configured to receive a bracket used for mounting an end cap 616 (see Fig. 49 and Fig. 50). According to the illustrated embodiment, the base of the connecting component 610 is symmetrical and has two identical slots 634; the end of the lower support bar 614 and the end of the mounting bracket are similarly shaped and sized to fit into the slots 634. The base of the connecting component 610 may also have any number of threaded holes 636 (in Fig. 48) or inserts for receiving threaded connectors for coupling the lower support bars 614 and the mounting brackets with the connecting components 610. As in Fig. 44, each of the two outermost connecting components 610 has an end cap 616 and a lower support bar 614 attached thereto, while the middle connecting component 610 has two lower support bars 614 and no end cap 616 attached thereto. In the illustrated embodiment, the end caps 616 are decorative end caps that cooperate to form an exposed sidewall surface for the lower assembly 602 when it is deployed (see Fig. 2 and Fig. 69-72).

[0076] The interconnect component 610 includes a base 638 having an outwardly facing surface 640 and an inwardly facing surface 642. In the illustrated embodiment, the edges of the slots 634 terminate at the outwardly facing surface 640, and the interconnect component 610 includes a suitably configured and arranged protrusion structure 644 extending in a direction away from the inwardly facing surface 642. In other words, the protrusion structure 644 rises above and extends from the inwardly facing surface 642. The disclosed implementation of the protrusion structure 644 includes two similarly shaped, sized, and configured protrusions (located on or near either side of the interconnect component 610). Referring to Fig. 47, the protrusion structure 644 has an irregular side profile shape characterized by: a lower portion resembling a truncated triangle; and an upper portion resembling a truncated inverted triangle. The lower portion extends upward from the base 638 and extends from its greatest width (the horizontal dimension in Fig. 47) at or near the base 638 to its smallest width in a neck region 646. The neck region 646 corresponds to the transition between the upper and lower regions of the protruding structure 644. The upper region transitions from its smallest width in the neck region 646 to its greatest width at or near the upper surface 648 of the protruding structure 644. The angled side walls of the upper region form at least one chamfered portion 650 of the irregular side profile of the protruding structure 644.

[0077] The connecting component 610 also includes a bolt retainer 652 that is shaped, sized, and positioned to receive a guide bolt (see Fig. 49 and Fig. 50). As further described below, the guide pin is shaped, sized, configured, and positioned to engage a guide rail when the lower assembly 602 is installed for use with a load-bearing support structure. The guide pin moves along a path defined by the guide rail, which in turn causes the connecting component 610 and the corresponding lower assembly 602 to move in a predetermined and limited manner.

[0078] Fig. 49 and Fig. 50 are perspective views showing the assembly steps associated with the manufacture of the lower assembly 602. Fig. 49 shows a connecting element 610 after installation of a guide pin 654 into the pin carrier 652. Fig. Figure 49 also shows a hinge pin 656 installed in one of the two hinge structures of the connecting component 610. The guide pin 654 and the hinge pin 656 can be connected to their respective support structures using any suitable technique, such as press-fitting, threading, welding, gluing, or the like. It is understood that the hinge pins 656 are used to connect a plurality of connecting components 610 in series. As explained below, the hinge pins 656 can also be used to connect the connecting components 610 to the hinge structures of a leading edge assembly. Fig. 49 also shows a bracket 658 and threaded fasteners 660 that can be used to attach an end cap 616 to the bracket 658. Fig. 49 also shows an end portion of the lower support bar 614, which is shaped and sized to fit into one of the slots 634 of the connecting component 610.

[0079] Fig. 50 shows a side of a lower assembly 602 after the Fig. 49 have been installed. Threaded fasteners 662 may be used to secure the lower support bar 614 to the connecting component 610 and to secure the bracket 658 (with the end cap 616) to the connecting component 610. With respect to Fig. 44, the opposite side of the lower assembly 602 is constructed similarly, using a second lower support bar 614. The two lower support bars 614 are connected to a third part of the connecting component 610.

[0080] Fig.51-56 relate to an exemplary embodiment of an upper assembly 702 suitable for use with the disclosed second embodiment. Fig. 51 is a perspective top view of the upper assembly 702, and the Fig. 52-56 illustrate various components and subassemblies of the upper assembly 702. As explained in more detail below, embodiments of a load-bearing support structure utilize a plurality of these upper assemblies 702 hinged together in series to form part of the deformable support mechanism. Some of the structures, features, and functional characteristics of the upper assembly 702 are similar, identical, or equivalent to those described above for the lower assembly 602. For simplicity and brevity, such similar, identical, or equivalent aspects will not be redundantly described in detail herein in connection with the upper assembly 702.

[0081] The illustrated embodiment of the upper assembly 702 includes, without limitation, connecting components 710 and upper support bars 714 (or equivalent support subcomponents) that cooperate when deployed to form a deployable support surface. These major components of the upper assembly 702 are interconnected by suitable hardware, subcomponents, and / or material.

[0082] In this particular embodiment, the connecting components 710 are identical, and the upper assembly 702 includes three of them (one at or near the left side, one at or near the right side, and one between the left and right sides). Although in Fig. 51 illustrates an assembly having three interconnection components 710, alternative embodiments of an upper assembly may include only one upper interconnection element or more than three upper interconnections, depending on the particular application, the intended use of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-carrying capacity.

[0083] As shown and described in more detail below, the connecting components 710 are configured and arranged to form a front hinge structure of the upper assembly and a rear hinge structure of the upper assembly. The front hinge structure is located at or near the front edge portion of the upper assembly, and the rear hinge structure is located at or near the rear edge portion of the upper assembly. The front hinge structure of the upper assembly 702 is configured to have a front hinge pivot axis, and the rear hinge structure of the upper assembly 702 is configured to have a rear hinge pivot axis. When multiple upper assemblies 702 are hinged together in series, the hinge structures enable adjacent upper assemblies 702 to rotate relative to one another about the front and rear hinge pivot axes.This hinge arrangement facilitates compact (folded or bent) storage of the upper assembly 702, if desired.

[0084] In the Fig. 52-55 show various views of a connecting component 710 (for the upper assembly 702). Fig. 52 is a perspective view from above, Fig. 53 is a perspective view from below, Fig. 54 is a side view and Fig. Figure 55 is a top view. The figures illustrate the structural features that form the front hinge structure 726 and the rear hinge structure 728 of the upper assembly 702. The front and rear hinge structures 726, 728 are offset relative to one another to facilitate the connection / anchoring of multiple connection components 710 in series. The front hinge structure 726 includes a hole 730 formed therein for receiving a hinge pin, rod, bolt, or other suitably configured fastener or connecting element. Similarly, the rear hinge structure 728 includes a hole 732 for receiving another hinge pin, rod, bolt, fastener, connecting element, or the like.A line passing through the center of hole 730 corresponds to the rotation axis of the front hinge, and a line passing through the center of hole 732 corresponds to the rotation axis of the rear hinge.

[0085] The base of the connecting component 710 includes slots 734 formed therein. At least one slot 734 is shaped, sized, and configured to receive a portion of an upper support bar 714, and at least one slot 734 is shaped, sized, and configured to receive a magnetic block used to attach a flexible work surface component to the upper assembly (see Fig. 56). According to the illustrated embodiment, the base of the connecting component 710 is symmetrical and has two identical slots 734; the end of the upper support bar 714 and the magnet block are similarly shaped and sized to fit into the slots 734. The base of the connecting component 710 may also have any number of threaded holes 736 (in Fig. 55) or inserts for receiving threaded fasteners for coupling the upper support strips 714 with the connecting components 710. As shown in Fig. 51, each of the two outermost connecting components 710 has a magnetic block 737 and an upper support bar 714 attached thereto, while the middle connecting component 710 has two upper support bars 714 and no magnetic block 737 attached thereto.

[0086] The interconnect component 710 includes a base 738 having an outwardly facing surface 740 and an inwardly facing surface 742. In the illustrated embodiment, the edges of the slots 734 terminate at the outwardly facing surface 740, and the interconnect component 710 includes a suitably configured and arranged protrusion structure 744 extending in a direction away from the inwardly facing surface 742. In other words, the protrusion structure 744 rises above and extends from the inwardly facing surface 742. The disclosed embodiment of the protrusion structure 744 includes two similarly shaped, sized, and configured protrusions (located on or near either side of the interconnect component 710). Referring to Fig. 54, the protrusion structure 744 has an irregular side profile shape resembling a truncated, inverted triangle. The truncated triangular portion of the protrusion structure 744 extends upward from the base 738 and extends from its narrowest width (the horizontal dimension in Fig. 54) at or near the base 738 to its widest width at or near the top surface 748 of the projecting structure 744. The angled sidewalls of the frusto-triangular region form at least one chamfered portion 750 of the irregular side profile of the projecting structure 744.

[0087] The connecting component 710 also includes alignment tabs 751, which may be formed as part of the protrusion structure 744. As shown in the Fig. 52-55, the connecting component 710 includes four alignment tabs 751 located inside the protrusions. Each alignment tab 751 provides an outward-facing bearing surface that limits the side-to-side movement of the cooperating connecting elements 610. Furthermore, each trapezoidal protrusion of the connecting component 710 acts as a keystone when the upper assembly 702 is mated with the lower assembly 602 (see Fig. 76 and Fig. 77). When the assemblies 602, 702 are assembled in this manner, the alignment tabs 751 provide alignment assistance for the lower connecting elements 610 and prevent lateral displacement of the assembled connecting elements 610, 710.

[0088] The connecting component 710 also includes a bolt retainer 752 that is shaped, sized, and positioned to receive a guide bolt (see Fig. 56) that engages a guide rail when the upper assembly 702 is installed for use with a load-bearing support structure. The guide pin moves along a path defined by the guide rail, which in turn causes the connecting component 710 and the corresponding upper assembly 702 to move in a predetermined and limited manner.

[0089] Fig. 56 is an exploded perspective view showing the assembly steps associated with manufacturing the upper assembly 702. Fig. 56 shows a connecting component 710 after installation of a guide pin 754 into the pin holder 752. Fig. Figure 56 also shows a hinge pin 756 installed in one of the two hinge structures of the connecting component 710. The hinge pins 756 are used to connect a plurality of connecting components 710 in series. As explained further below, the hinge pins 756 can also be used to connect the connecting components 710 to the hinge structures of a leading edge assembly. Fig. Figure 49 also shows a magnetic block 737 that fits into one of the slots 734. The magnetic block 737 can be attached to the connecting component 710 by an interference fit, an adhesive or bonding material, a fastener, a snap fit, or the like. Fig. Figure 56 also shows an end portion of the upper support bar 714, which is shaped and sized to fit into one of the slots 734 of the connecting component 710. Threaded connectors 758 may be used to attach the upper support bar 714 to the connecting component 710.

[0090] Fig. 51 shows the upper assembly 702 after the Fig. 56 have been installed. The connecting components 710 on the left and right sides of the upper assembly 702 are each connected to an upper support bar 714 and a magnetic block 737. The two upper support bars 714 are connected to a third connecting component 710 (which does not include magnetic blocks 737).

[0091] Fig. 57-64 show an exemplary embodiment of a leading edge assembly 802 suitable for use with the disclosed second embodiment. Fig. 57 is a rear perspective view of the leading edge assembly 802, and the Fig. 58-64 illustrate various components and subassemblies of the leading edge assembly 802. Some of the structures, features, and functional characteristics of the leading edge assembly 802 are similar, identical, or equivalent to those described above for the lower assembly 602 and / or the upper assembly 702. For simplicity and brevity, such similar, identical, or equivalent aspects will not be redundantly described in detail herein in connection with the leading edge assembly 802.

[0092] The illustrated embodiment of the leading edge assembly 802 includes, without limitation: a right leading edge connection component 804; a left leading edge connection component 806; a center leading edge connection component 808; a mounting bracket assembly 812; and at least one fairing component (in Fig. 57 not shown, but in the Fig. 69-72) that includes or is made of decorative material. These major components of the leading edge assembly 802 are interconnected by suitable hardware, subcomponents, and / or material. Although in Fig. 57 illustrates an assembly having three leading edge connection components, alternative embodiments of a leading edge assembly may include only one leading edge connection component or more than three leading edge connection components, depending on the particular application, the intended application of the load-bearing support structure, the shape and size of the deployable support surface, and the various requirements for strength, durability, and load-carrying capacity.

[0093] As explained below with reference to the Fig. 65-68 and described in more detail, the connecting components 804, 806, 808 are suitably configured and arranged to form an upper hinge structure and a lower hinge structure for the leading edge assembly 802. The upper hinge structure is arranged and configured for compatibility with the connecting components 710 of an upper assembly 702, and the lower hinge structure is arranged and configured for compatibility with the connecting components 810 of a lower assembly 602. These hinge structures facilitate rotation of the corresponding upper and lower assemblies 702, 602 about the respective rotational axes defined by the hinge structures.

[0094] In the Fig. 58-61 illustrate various views of the right leading edge connection component 804. The left leading edge connection component 806 is similarly configured, with certain features and structures rearranged to accommodate the asymmetric nature of the right and left leading edge connection components 804, 806. Fig. 58 is a perspective view from behind, Fig. 59 is a perspective view from the front, Fig. 60 is a view from behind and Fig. Figure 61 is a bottom view. The figures illustrate the structural features that form the upper hinge structure 816 and the lower hinge structure 818 of the leading edge assembly 802. The upper and lower hinge structures 816, 818 are offset relative to each other to facilitate the interconnection of the upper and lower assemblies 702, 602. The upper hinge structure 816 includes a hole 822 formed therein for receiving a hinge pin, rod, bolt, or other suitably configured fastener or connecting member. Similarly, the lower hinge structure 818 includes a hole 824 for receiving another hinge pin, rod, bolt, fastener, connecting member, or the like.A line passing through the center of the hole 822 corresponds to an upper hinge pivot axis 826, and a line passing through the center of the hole 824 corresponds to a lower hinge pivot axis 828.

[0095] The illustrated embodiment of the connecting component 804 includes a contoured recess 830 formed therein. The contoured recess 830 curves from the top to the back of the connecting component 804, as shown in Fig. 59. The contoured recess 830 is shaped, sized, and positioned to receive an end portion of the mounting bracket assembly 812 (see Fig. 64). For this purpose, the connecting component 804 may include any number of threaded holes 832 or threaded inserts to facilitate attachment to the mounting bracket assembly 812. The connecting component 804 may also include any number of additional threaded inserts, threaded holes, and / or through-holes 834 to facilitate attachment of other components during assembly of the resulting support mechanism, e.g., trim pieces, mounting hardware, a handle or knob, a decorative exterior surface, or the like. Although not used in the illustrated embodiment, the sides of the connecting component 804 may be suitably configured to accommodate a decorative end cap.

[0096] The connecting component 804 includes structural locking features 840 for the leading edge assembly 802. In particular, the structural locking features 840 are shaped, sized, arranged, and configured to cooperate with the boss structure 644 of a connecting component 610 of the lower assembly 602 and / or with the boss structure 744 of a connecting component 710 of the upper assembly 702. In the illustrated embodiment, the structural locking features 840 have a side profile shape that matches the side profile shape of the boss structure 644 (a triangular notch receives the upper portion of the boss structure 644, a triangular tip receives the neck region 646 of the boss structure 644, and the long sloped wall follows the sloped sidewall of the boss structure 644).This locking arrangement holds the connecting component 610 in position and prevents rotation of the connecting component 610 relative to the connecting element 804 about the hinge axis. In the . Fig. 66 and Fig. 67 shows the connection components 610 with the corresponding connection components 804, 806 and 808.

[0097] Fig. 62 is a rear perspective view of one embodiment of the central leading edge connecting component 808, and Fig. 63 is a top view of the interconnect component 808. The interconnect component 808 has many of the features, structures, and functions of the interconnect component 804, and these common aspects will not be redundantly described in detail here. For example, the interconnect component 808 includes: an upper hinge structure 846 providing the upper hinge pivot axis 826; a lower hinge structure 848 providing the lower hinge pivot axis 828; contoured recesses 850 for receiving mounting bracket assemblies 812; and structural locking features 852 that cooperate with structural features of the interconnect component 610 of the lower assembly 602. In particular, the center leading edge interconnect component 808 includes two contoured recesses 850 to facilitate mating of two bracket assemblies 812, as shown in FIGS. Fig. 57 and 65-68 shown.

[0098] With reference to Fig. 57 and Fig. 64, the leading edge assembly 802 is manufactured by connecting two mounting bracket assemblies 812 with the connecting components 804, 806, 808 in the Fig. 57. Threaded fasteners 854 may be used to secure the ends of the mounting bracket assemblies 812 to their respective connecting components. Fig. 65-70 are perspective views illustrating manufacturing steps involving the leading edge assembly 802. Fig. Figure 65 shows the leading edge assembly 802 and a lower assembly 602 before they are joined together. For better visibility, one of the end caps 616 is missing from the illustrated lower assembly 602. Fig. Figure 66 shows the leading edge assembly 802 and the lower assembly 602 connected together. To this end, the front hinge structures 626 of the lower assembly 602 mate with the lower hinge structures 818 of the leading edge assembly 802 and are held together with suitable hinge pins, bolts, or rods. Fig. Figure 67 shows the condition after insertion of an upper assembly 702. To this end, the front hinge structures 626 of the upper assembly 702 mate with the upper hinge structures 816 of the leading edge assembly 802 and are held together with suitable hinge pins, bolts, or rods. When assembled in this manner, the rear portions of the projection structures 644 mate with and engage the front portions of the projection structures 744, thereby preventing rotation of the upper assembly 702 relative to the lower assembly 602 about the hinge axis. Fig. 68 shows the state after attaching the second end cap 616 to the lower assembly 602.

[0099] Fig. 68 shows three end link components 610 of three corresponding chain assemblies (consisting of a plurality of lower assemblies 602 connected in series) and three end link components 710 of three corresponding chain assemblies (consisting of a plurality of upper assemblies 702 connected in series). Fig. 69 is a front perspective view showing the leading edge assembly 802 after a number of lower assemblies 602 and a number of upper assemblies 702 have been joined together. Fig. Figure 69 shows the components in the deployed state after the upper and lower assemblies 702, 602 have been connected together in a load-bearing configuration.

[0100] Fig. 69 also shows a portion of a flexible work surface component 860 overlying the deployed upper assemblies 702. The flexible work surface component 860 may be made from a thin, flexible metal sheet to which an outer layer of decorative material is applied. Alternatively or additionally, the flexible work surface component 860 may be made from any flexible and pliable material that can be coated, painted, or otherwise processed to provide a suitable decorative appearance, pattern, or graphic on its outer surface. According to the illustrated embodiment, a front portion 862 of the flexible work surface component 860 is connected to the leading edge assembly 802.The leading portion 862 may be secured to the leading edge assembly 802 using one or more of the following: a mounting bracket, fasteners, a clamp, a bonding agent, an adhesive, or the like. Fig. 70 shows a condition after attachment of a front trim component 864 to the leading edge assembly 802. In certain embodiments, the front trim component 864 is attached to the leading edge assembly 802 using fasteners that pass through the holes 834 in the connecting components 804, 806, 808. When the support mechanism is extended, at least a portion of the flexible work surface component 860 overlies a series of extended upper assemblies 702 to form an extended load-bearing work surface. When the support mechanism is retracted for storage, at least a portion of the flexible work surface component separates from the upper assemblies 702 for storage in response to the concerted movement of the upper and lower assemblies 702, 802 along a stowage path.In the exemplary embodiment shown here, the magnetic blocks 737 of the upper assemblies 702 magnetically couple the underside of the flexible work surface component 860 to the upper assemblies 702 when the support mechanism is extended. The magnetic connections are released upon retraction of the support mechanism, facilitating separation of the flexible work surface component 860 for compact storage, if desired. In this regard, FIGS. Fig. 76-79 a portion of the flexible work surface component 860 separated from the underlying upper assemblies 702.

[0101] Fig. 71 and Fig. 72 show an exemplary embodiment of a deformable load-bearing support mechanism 900 that utilizes a plurality of the lower assemblies 602, a plurality of the upper assemblies 702, and the leading edge assembly 802. The support mechanism 900 corresponds to the Fig. 1 and Fig. 2 and can be used with the load-bearing support structure 100 shown therein. For simplicity and to facilitate description, the support mechanism 900 is shown without any surrounding structure or associated bearing unit.

[0102] The support mechanism 900 includes a plurality of upper assemblies 702 hinged together in series and a plurality of lower assemblies 602 hinged together in series. As shown in the Fig. 76-79, the coupled assembly of upper assemblies 702 terminates with a terminal upper assembly 702-1, and the coupled assembly of lower assemblies 602 terminates with a terminal lower assembly 602-1. The end assemblies 602-1, 702-1 are connected to the leading edge assembly 802 via their respective end connection components 610, 710. More specifically, the connection components 610 of the terminal lower assembly 602-1 and the connection components 710 of the terminal upper assembly 702-1 are connected to the connection components 804, 806, 808 of the leading edge assembly 802.

[0103] When assembled and deployed as described herein, the lower link components 610 and the upper link components 710 are configured to function as chain links hinged together in series. The illustrated embodiment includes three upper chain assemblies (left, right, and center) formed by the upper link components 710 and three lower chain assemblies (left, right, and center) formed by the lower link components 610. Each upper chain link, realized with the upper link components 710, has outward-facing structural features and inward-facing structural features opposite the outward-facing structural features.Likewise, each lower chain link realized with the lower connecting components 610 has outward-facing structural features and inward-facing structural features opposite its outward-facing structural features.

[0104] The inwardly facing structural features of the upper link components 710 (e.g., the protrusion structures 744) and the inwardly facing structural features of the lower link components 610 (e.g., the protrusion structures 644) are configured to releasably connect in response to joint movement of the upper and lower track assemblies along a predefined deployment path. Conversely, the inwardly facing structural features of the upper link components 710 and the inwardly facing structural features of the lower link components 610 are configured to separate and decouple in response to joint movement of the upper and lower track assemblies along a predefined stowage path.

[0105] A deployed number of the upper assemblies 702 together form a deployable support surface of the support mechanism 900. More specifically, the upper support bars 714 together form the deployable support surface (which may be covered by the flexible work surface component 860). When the upper and lower track assemblies are deployed and coupled together as described herein, the corresponding projection structures 744, 644 interlock to be self-supporting. As a result, the deployable work surface is load-bearing in the deployed position. According to the illustrated embodiment, the extended portion of the support mechanism 900 enables loading of the work surface and loading of the structure below / opposite the work surface.

[0106] Fig. 76 and Fig. 77 show how the upper and lower connection components 710, 610 cooperate with each other to switch between an uncoupled and separated state and a coupled and locked state. For clarity and simplicity, Fig. 76 and Fig. 77 Some components that appear in other figures are not shown. Fig. 76 is a side view corresponding to a first position that may represent an initial state prior to deployment of the morphable support mechanism 900. Fig. 77 is a side view corresponding to a second position, which may represent an intermediate state after the start of the operation.

[0107] In Fig. 77, the boss structure of the upper assembly 702-1 is fully coupled and interlocked with the boss structures of the lower assemblies 602-1, 602-2. More specifically, the boss structures of the two adjacent lower connecting components 610 flank and engage the boss structure of an upper connecting component 710. Similarly, the boss structure of the lower assembly 602-2 is flanked by the boss structures of the two upper assemblies 702-1, 702-2. As explained above, the tapered portions and features of the boss structures interlock, fit together, and interlock with each other when the support mechanism 900 is in the extended state. This interlocking assembly is desirable to hold the upper and lower assemblies 702, 602 in place and prevent rotation of the assemblies 702, 602 relative to each other.

[0108] The sequence of Fig. 76 and Fig. Figure 77 shows how the protruding structures of the upper and lower assemblies 702, 602 interact dynamically and interlock in response to a concerted movement of the upper and lower assemblies 702, 602 along a predefined deployment path. The reverse sequence of Fig. 76 and Fig. Figure 77 shows how the projection structures of the upper and lower assemblies 702, 602 dynamically interact and release in response to the joint movement of the upper and lower assemblies 702, 602 along a predefined stowage path. In this particular embodiment, the deployment and stowage paths follow a common path, but in opposite directions. As shown in Figures Fig. 76 and Fig. As shown in Figure 77, movement of the upper and lower assemblies 702, 602 along the deployment path causes them to approach each other and causes the lower interconnect components 610 to pivot and move into alignment with two flanking elements of the upper interconnect components 710. Further movement along the deployment path brings the projecting structures into the fully coupled state.

[0109] As in the Fig. 73-75, 78, and 79, the support mechanism 900 cooperates with a guide rail assembly having at least one guide rail 910. The disclosed embodiment includes three guide rails 910—one for the left-side track assemblies, one for the right-side track assemblies, and one for the middle track assemblies. The guide rail assembly is suitably configured to receive the upper and lower assemblies 702, 602 and is adapted to allow sliding movement of the upper and lower assemblies 702, 602 as required for deployment and stowage of the morphable support mechanism 900.More specifically, each guide rail 910 is configured to receive an upper track assembly (formed from the upper link components 710) and a lower track assembly (formed from the lower link components 610), and each guide rail 910 accommodates sliding movement of the track assemblies as needed. To this end, each guide rail 910 is shaped, sized, and arranged in a desired manner to define and provide the predefined deployment and stowage paths for the upper and lower assemblies 702, 602.

[0110] Each guide rail 910 is also shaped, sized, arranged, and configured to transition the projection structures of the upper assembly 744 and the projection structures of the lower assembly 644 from an uncoupled state to a coupled state in response to joint movement of the chain assemblies along the deployment path defined by the guide rail 910. Likewise, each guide rail 910 is shaped, sized, arranged, and configured to transition the projection structures 744 of the upper assembly and the projection structures 644 of the lower assembly from the coupled state to the uncoupled state in response to joint movement of the chain assemblies along the stowage path defined by the guide rail 910. Fig. 78 and Fig. Figure 79 shows the coupling / decoupling processes that result from such concerted movements.

[0111] Each guide rail 910 of the illustrated embodiment includes various structural features that support and guide the lower and upper assemblies 602, 702 as they move along the guide rail 910. Depending on the embodiment, the guide rail 910 may include, without limitation and in any combination, any of the following structural features: one or more channels, one or more flanges, one or more rails, one or more tracks, one or more tunnels, one or more slots, one or more keys / wedges, one or more projections, one or more ribs, one or more grooves, or the like.

[0112] Although not always required, the illustrated embodiment of the guide rail 910 includes a first keyway 920 formed therein, a second keyway 922 formed therein, and a third keyway 924 formed therein. As shown in the cross-sectional view of Fig. 75, the first and second keyway slots 920, 922 merge at an intersection 926 that is continuous with the third keyway slot 924. Thus, the third keyway 924 merges and splits into the first and second keyways 920, 922. The guide rail 910 also includes an upper slot 928 and a lower slot 930. The upper slot 928 provides an opening for direct access to the first keyway slot 920 and for direct access to the third keyway slot 924 (from above). The lower slot 930 provides an opening for direct access to the second keyway slot 922 and for direct access to the third keyway slot 924 (from below).

[0113] The third keyway 924 receives the guide pins 654, 754 of the connecting components 610, 710; the upper and lower slots 928, 930 receive the upper and lower pin holders 752, 652 (see Fig. 50 and Fig. 56). This assembly allows the guide pins 654, 754 and the pin holders 652, 752 to move in a constrained and predefined manner defined by the third keyway slot 924. The first keyway slot 920 receives the guide pins 754 of the upper connecting components 710, and the upper slot 928 receives the pin holders 752 of the upper connecting components 710. This assembly allows the guide pins 754 and the pin holder 752 to move in a limited and predefined manner defined by the first keyway slot 920. The second keyway slot 922 receives the guide pins 654 of the lower connecting component 610, and the lower slot 930 receives the lower pin supports 652. This assembly allows the guide pin 654 and the pin holder 652 to move in a predefined manner defined by the second keyway slot 922.

[0114] In particular, the guide pin 654 and / or the pin retainer 652 of the lower link component 610 represent a wedge arrangement configured to engage and slide within the keyway 922 when the lower chain assembly (the series of lower link components 610) is uncoupled from the upper chain assembly (the series of upper link components 710). Likewise, the guide pin 754 and / or the pin carrier 752 of the upper link component 710 represent another wedge arrangement configured to engage and slide within the keyway 920 when the upper chain assembly is uncoupled from the lower chain assembly. Both wedge assemblies engage and slide within the keyway 924 when the upper and lower chain assemblies are coupled together. See, for example, Fig. 78 and Fig. 79. In this manner, the guide pins 654 cooperate with the keyway 922 to maintain at least a portion of the lower assemblies 602 in a stowed state on the guide rail 910. Similarly, the guide pins 754 cooperate with the keyway 920 to maintain at least a portion of the upper assemblies 702 in a stowed state on the guide rail 910.

[0115] The guide rail 910 has a main longitudinal axis 936 which is generally defined by a line centered in the interior of the guide rail 910 (see Fig. 73, which shows the entry and exit of the longitudinal axis 936 from the guide rail 910). In certain exemplary embodiments, the guide rail 910 has a curved main longitudinal axis 936, which enables folded storage of the upper and lower chain assemblies when the projection structures 744, 644 are decoupled from each other, and thus folded storage of the corresponding lower and upper assemblies 602, 702. In the Fig. 73-79 only the transition area of ​​the guide rail 910 is shown, which has a curved shape. Although the guide rails 910 in Fig. 71 are not shown, the curved shape of the retracted and stowed part of the support mechanism 900 is clearly visible. Fig. In the embodiment shown in Figure 71, the guide rails 910 are suitably curved so that the upper and lower assemblies 702, 602 are constrained to follow the curved paths as shown. In certain embodiments, the guide rail assembly, one or more of the individual guide rails 910, and / or another guiding or storage feature may be used to receive, guide, and store a portion of the flexible work surface component 860 when the support mechanism 900 is in the retracted state.

[0116] The guide rail 910 includes a curved gooseneck portion 940 that serves as a transition for coupling / uncoupling the lower and upper assemblies 602, 702. In the illustrated embodiment, the curved gooseneck portion 940 accommodates a desired predefined boss shape of the first keyway 902 (see Fig. 75) required to raise and lower the upper assemblies 702 relative to the lower assemblies 602 during joint movement of the assemblies. The boss shape of the first keyway 920 ensures that the upper connecting components 710 engage the lower connecting components 610 in the correct location during use (see Fig. 76 and Fig. 77). The keyways 920, 922 can be brought closer together below the curved gooseneck portion 940 while maintaining the desired spacing between the lower and upper assemblies 602, 702 (see Fig. 75). The curved gooseneck portion 940 enables the transition of the lower and upper assemblies 602, 702 from the uncoupled state to the coupled state (and vice versa) in response to concerted movement during deployment and stowage, as described above with reference to the Fig. 76 and Fig. 77. The shape of the curved gooseneck portion 940 and the variable spacing between the first and second keyways 920, 922 urge the lower and upper assemblies 602, 702 into the desired positions when moved together during extension and retraction.

[0117] As mentioned above with reference to the Fig. 1 and Fig.2, a load-bearing support structure utilizing the support mechanism 900 may include a suitably configured storage unit that fully or partially surrounds the guide rails 910. The storage unit may be shaped and sized to facilitate stowing the morphable support mechanism 900 (including the track assemblies, the upper and lower assemblies 702, 602, etc.) in the stowed state. Furthermore, the storage unit may have an opening defined or formed therein, the opening being shaped and sized to accommodate the passage of the morphable support mechanism 900 when the upper and lower assemblies 702, 602 are interconnected in the deployed state. Additional or optional features

[0118] Various embodiments of the invention, including the first and second embodiments described above, may implement particular features, functions, and / or structures suitable for the particular application or use case. This section describes several additional or optional features.

[0119] Curved Support Surface - The first and second embodiments described above have a relatively flat and straight support surface (when unfolded). In this respect, the first and second embodiments are suitable for use as a table surface, desk surface, wall, pocket door, armrest, seat pan, or the like. According to alternative embodiments, the deformable support mechanism can be configured to provide a curved or angled (non-flat, non-planar) support surface when deployed. To achieve a non-planar support surface, the upper and lower assemblies can be configured asymmetrically. For example, the upper connecting components can be longer or shorter than the corresponding lower connecting components, resulting in a bent or curved assembly after the upper and lower assemblies are connected.

[0120] Deployment Scheme - In accordance with certain implementations, the morphable support mechanism can be manually deployed to the desired position and manually returned to its original stowed position. For example, the leading edge assembly can include a handle, recess, or hole that accommodates a user's hand or fingers, or tabs that can be used to pull / push the support mechanism as needed. In certain embodiments, the movement of the support mechanism can be assisted (e.g., by springs, a pneumatic mechanism, or similar). Alternatively, or additionally, the support mechanism can be electronically controlled by a suitably configured motor system.

[0121] Locking Function - The support mechanism is characterized by a fully stowed and a fully deployed position. In certain embodiments, the support mechanism can also be moved to one or more intermediate positions between the fully retracted and fully deployed positions. The intermediate positions can be predefined (discrete lockable positions), or the support structure can be configured so that the support mechanism can be continuously adjusted and locked in any position. For this purpose, the support structure can include one or more locking features or locking mechanisms to hold the support mechanism in position after deployment.For example, the support structure may include a manually operated or electronically activated subsystem that physically limits the movement of the upper and lower assemblies relative to their respective guide rails, thus maintaining them in the desired extended state.

[0122] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that a wide variety of variations exist. It should also be appreciated that the exemplary embodiment(s) described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description is intended to provide one skilled in the art with a convenient guide for practicing the described embodiment or embodiments. It is to be understood that various changes may be made in the function and assembly of the elements without departing from the scope of applicability defined by the claims, which includes known equivalents and equivalents foreseeable at the time of filing this patent application.

Claims

[1] A deformable support mechanism for a load-bearing support structure, the deformable support mechanism comprising: a first chain assembly comprising a plurality of first chain links pivotally connected in series, each of the first chain links comprising: a first base having an outwardly facing surface and an inwardly facing surface; and a first protrusion structure extending in a direction away from the inwardly facing surface of the first base, the first protrusion structure having a first irregular side profile shape; a second chain assembly comprising a plurality of second chain links pivotally connected in series, each of the second chain links comprising: a second base having an outwardly facing surface and an inwardly facing surface; and a second protrusion structure extending in a direction away from the inwardly facing surface of the second base, the second protrusion structure having a second irregular side profile shape, the first and second protrusion structures configured to releasably couple together in response to concerted movement of the first and second chain assemblies along a predefined deployment path, and the first and second protrusion structures configured to separate and uncouple from each other in response to concerted movement of the first and second chain assemblies along a predefined stowage path; and a plurality of support subcomponents each coupled to the plurality of first chain links, wherein a deployed number of the support subcomponents cooperate to form a deployable support surface, and wherein the first and second projection structures interlock to be self-supporting when deployed such that the deployable support surface is load-bearing. [2] The deformable support mechanism according to claim 1, wherein: the first irregular side profile shape of the first protrusion structure comprises at least one chamfered first portion; the second irregular side profile shape of the second protrusion structure comprises at least one chamfered second portion; and in the deployed state, the at least one beveled first section mates with and engages the at least one beveled second section. [3] The deformable support mechanism according to claim 1, wherein: when the first and second chain assemblies are deployed, the second projection structures of two adjacent second chain links flank and engage the first projection structure of one of the first chain links. [4] The deformable support mechanism according to claim 1, wherein: the first chain assembly ends with a last first chain link from the plurality of first chain links; the second chain assembly ends with a last second chain link of the plurality of second chain links; and the deformable support mechanism further comprises a leading edge link connected to the last first chain link and the last second chain link. [5] The deformable support mechanism of claim 4, further comprising: a leading edge assembly connected to the leading edge member and having decorative material forming an exposed surface of the leading edge assembly. [6] The deformable support mechanism of claim 1, further comprising a plurality of decorative end caps coupled to a corresponding plurality of the second chain links of the second chain assembly, the decorative end caps cooperating to provide an exposed sidewall surface when deployed. [7] The deformable support mechanism of claim 1, further comprising a guide rail configured to receive the first and second chain assemblies, the guide rail accommodating sliding movement of the first and second chain assemblies, the guide rail being shaped and arranged to provide the predefined deployment and stowage paths for the first and second chain assemblies. [8] The deformable support mechanism according to claim 7, wherein: the guide rail is shaped and arranged to transition the first and second projection structures from an uncoupled state to a coupled state in response to concerted movement of the first and second chain assemblies along the predefined deployment path; and the guide rail is shaped and arranged to transition the first and second projection structures from the coupled state to the uncoupled state in response to concerted movement of the first and second chain assemblies along the predefined accumulation path. [9] The deformable support mechanism of claim 8, wherein at least a portion of the guide rail has a curved major longitudinal axis to enable folded storage of the first and second chain assemblies with the first and second projection structures decoupled from each other. [10] A deformable support mechanism for a load-bearing support structure, the deformable support mechanism comprising: a first chain assembly comprising a plurality of first chain links pivotally connected in series, each of the first chain links comprising: a first base having an outwardly facing surface and an inwardly facing surface; and a first protrusion structure extending in a direction away from the inwardly facing surface of the first base, the first protrusion structure having a first irregular side profile shape; a second chain assembly comprising a plurality of second chain links pivotally connected in series, each of the second chain links comprising: a second base having an outwardly facing surface and an inwardly facing surface; and a second protrusion structure extending in a direction away from the inwardly facing surface of the second base, the second protrusion structure having a second irregular side profile shape; and wherein the first and second projection structures are configured to be releasably connected to one another in response to joint movement of the first and second chain assemblies along a predefined deployment path; wherein the first and second projection structures are configured to separate and decouple from each other in response to joint movement of the first and second chain assemblies along a predefined accumulation path; and wherein the first and second projection structures are interlocked to be self-supporting when deployed, such that a deployed arrangement of the first and second chain assemblies is load-bearing. [11] The deformable support mechanism of claim 10, further comprising a guide rail configured to receive the first and second chain assemblies, the guide rail accommodating sliding movement of the first and second chain assemblies, and the guide rail configured to provide the predefined deployment and stowage paths. [12] The deformable support mechanism according to claim 11, wherein: the guide rail has a first keyway and a second keyway formed therein; at least some of the first chain links have a first key arrangement configured to engage and slide in the first keyway when the first chain assembly is uncoupled from the second chain assembly; and at least some of the second chain links have a second key arrangement configured to engage and slide within the second keyway when the second chain assembly is uncoupled from the first chain assembly. [13] The deformable support mechanism according to claim 12, wherein: the first key assemblies cooperate with the first keyways to maintain at least a portion of the first chain assembly on the guide rail in a stowed condition; and the second key arrangement cooperates with the second keyways to maintain at least a portion of the second chain assembly on the guide rail in a stowed condition. [14] The deformable support mechanism of claim 11, further comprising a bearing unit at least partially surrounding the guide rail, the bearing unit being shaped and sized to enable storage of the first and second chain assemblies in a stowed condition. [15] The deformable support mechanism of claim 14, wherein the bearing unit has an opening defined therein shaped and sized to accommodate the passage of the first and second chain assemblies when connected together in a deployed condition. [16] A deformable load-bearing structure having: a plurality of upper assemblies hinged together in series, each comprising: an upper assembly leading edge portion; an upper assembly front hinge structure located at the upper assembly leading edge portion; an upper assembly trailing edge portion; an upper assembly rear hinge structure located at the upper assembly trailing edge portion; and an upper assembly boss structure; wherein the front hinge structure of the upper assembly is configured to provide a front hinge rotation axis of the upper assembly, and the rear hinge structure of the upper assembly is configured to provide a rear hinge rotation axis of the upper assembly; a plurality of lower assemblies hinged together in series, each comprising: a lower assembly leading edge portion; a lower assembly front hinge structure located at the lower assembly leading edge portion; a lower assembly trailing edge portion; a lower assembly rear hinge structure located at the lower assembly trailing edge portion; and a lower assembly boss structure; wherein the front hinge structure of the lower assembly is configured to form a front hinge axis of the lower assembly, and the rear hinge structure of the lower assembly is configured to form a rear hinge axis of the lower assembly; a guide rail assembly configured to receive the upper and lower assemblies, the guide rail assembly enabling sliding movement of the upper and lower assemblies; wherein the projection structures of the upper assembly and the projection structures of the lower assembly are configured to be releasably coupled together in response to concerted movement of the upper and lower assemblies along a deployment path defined by the guide rail assembly, and the upper and lower assemblies interlock to be self-supporting and load-bearing in the deployed state; and wherein the projection structures of the upper assembly and the projection structures of the lower assembly are configured to separate and decouple from each other in response to concerted movement of the upper and lower assemblies along a path defined by the guide rail assembly. [17] The deformable load-bearing support structure of claim 16, wherein: the guide rail is shaped and arranged to transition the projection structures of the upper assembly and the projection structures of the lower assembly from an uncoupled state to a coupled state in response to concerted movement of the first and second chain assemblies along the deployment path; the guide rail is shaped and arranged to transition the projection structures of the upper assembly and the projection structures of the lower assembly from the coupled state to the uncoupled state in response to concerted movement of the first and second assemblies along the accumulation path; and at least a portion of the guide rail has a curved major longitudinal axis to accommodate folded support of the first and second assemblies with the upper assembly projection structures decoupled from the lower assembly projection structures. [18] The deformable load-bearing support structure of claim 16, wherein: the majority of upper assemblies end with a final upper assembly; the majority of the lower assemblies end with a final lower assembly; and the deformable load-bearing support structure further comprises a leading edge assembly connected to the last upper assembly and the last lower assembly. [19] The deformable supporting structure of claim 18, further comprising: a flexible work surface component having a front portion connected to the front edge assembly; wherein at least a portion of the flexible work surface component overlies a plurality of deployed upper assemblies to form a deployed load-bearing work surface; and wherein at least a portion of the flexible work surface component separates from the upper assemblies for storage in response to concerted movement of the upper and lower assemblies along the stowage path. [20] The deformable load-bearing support structure of claim 19, wherein the flexible work surface component includes an outer layer of decorative material. [21] The deformable load-bearing support structure of claim 16, wherein: the upper assembly projection structure has at least one chamfered first portion; the lower assembly projection structure has at least one chamfered second portion; and in the deployed state, the at least one beveled first section mates with and engages the at least one beveled second section.

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