Body support structure, armrest and methods for the use and assembly thereof

Abstract

A body support structure includes a tilt control having a tilt member pivotally connected to a base member. A seat is connected to the tilt member and includes a seat pan having an upper support member and a side skirt extending downwardly from the upper support member. A flex region may be defined at least in part by a plurality of slots formed in the upper support member and the side skirt. A shell, having a flex region, may be disposed under, and connected to, the seat pan. A backrest includes a front shell and a rear shell coupled to the front shell, with front and rear cover members overlying the shells and having edge portions disposed between the first and second peripheral edges and define a peripheral seam therebetween. An armrest includes a support member and an arm cap with a carrier engaged with the support member.

Description

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 63 / 756,939, filed Feb. 11, 2025, the entire disclosure of which is hereby incorporated herein by reference.FIELD OF THE INVENTION

[0002] The present application relates generally to a body support structure such as a chair, an armrest for use with a body support structure, and to the methods for the use and assembly thereof.BACKGROUND

[0003] Body supporting structures, including for example, office chairs, vehicular and aircraft seating, sofas, beds and other pieces of furniture, are often configured with a relatively rigid seat and back shells or frames, which may support a cushion. While some deformation from the user's weight may be absorbed by the cushion, the underlying structure may not be capable of flexing and thereby providing additional adaptation and comfort. In addition, backrests on such chairs are typically not configured with a cushion on the rear side thereof, such that the surface may be susceptible to damage when impacted during use.

[0004] Furthermore, while some body support structures may be configured with armrests, such armrests may present a relatively hard surface to the user, for example when made with an exposed metal surface. It may be difficult to reliably configure such armrests with a pad to provide comfort to the user. Often, the pad is positioned above the armrest, and / or may be susceptible to snagging and / or severance from the armrest.SUMMARY

[0005] The present invention is defined by the following claims, and nothing in this section should be considered to be a limitation on those claims.

[0006] In one aspect, one embodiment of a body support structure includes a tilt control having a base member and a tilt member pivotally connected to the base member. A seat is connected to the tilt member and includes a seat pan having an upper support member and a side skirt extending downwardly from the upper support member. The seat pan includes a flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt, wherein a front portion of the seat pan is flexible relative to a rear portion of the seat pan about the flex region. A backrest is connected to the tilt member and is pivotable with the seat relative to the base. A pair of armrests each have an upper portion connected to the backrest and a lower portion connected to at least one of the seat and / or the tilt member.

[0007] In another aspect, one embodiment of a body support structure includes a tilt control and a seat connected to the tilt member. The seat includes a seat pan having an upper support member and a side skirt extending downwardly from the upper support member. The seat pan includes a first flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt. A front portion of the seat pan is flexible relative to a rear portion of the seat pan about the first flex region. A shell is disposed under, and connected to, the seat pan. The tilt control is disposed between the shell and the seat pan. The shell includes a second flex region, wherein a front portion of the shell is flexible relative to a rear portion of the shell about the second flex region as the front portion of the seat pan flexes relative to the rear portion of the seat pan about the first flex region.

[0008] In yet another aspect, one embodiment of a body support structure includes a seat and a backrest coupled to the seat. The backrest includes a front shell having a first peripheral edge, a rear shell coupled to the front shell and having a second peripheral edge, a front cover member overlying the front shell and having a first peripheral edge portion, a front cushion disposed between the front cover and the front shell, a rear cover overlying the rear shell and having a second peripheral edge portion, and a rear cushion disposed between the rear cover and the rear shell. The first and second peripheral edge portions are wrapped around and disposed between the first and second peripheral edges and define a peripheral seam therebetween.

[0009] In yet another aspect, an armrest includes a support member having a first track portion defining a first channel with a first mouth opening in a first translation direction, a second track portion defining a second channel with a second mouth opening in a second translation direction opposite the first translation direction, and a first catch member. An arm cap includes a carrier having a first portion with a first guide insertable through the first mouth and moveable in the first channel from a first disengaged position to a first engaged position, a second portion connected to the first portion and having a second guide insertable through the second mouth and moveable in the second channel from a second disengaged position to a second engaged position, and a second catch member. The first and second catch members are engaged as the second guide is moved in the second channel to the second engaged position.

[0010] Other methods of using and assembling the body support structure and armrest are also provided.

[0011] The various embodiments of body support structures, armrests and methods provide significant advantages over other body support structures, armrests, and methods for the manufacture, use and assembly thereof. For example, and without limitation, the seat pan provides a flexible support for a cushion and user, and when combined with a flexible shell, is capable of hiding the tilt control while providing flexure of the front portion of the seat relative to a rear portion thereof. The backrest also is provided with front and rear cushions, which improve the overall feel and appearance of the backrest, while also protecting the rear surface thereof. The armrest provides a unique support for an arm cap, which may be securely fixed to the support without tools. The support provides a robust attachment for the arm cap, which may be recessed in the support.

[0012] The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The various preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a front perspective view of one embodiment of a body support structure.

[0014] FIG. 2 is a front view of the body support structure shown in FIG. 1.

[0015] FIG. 3 is a rear view of the body support structure shown in FIG. 1.

[0016] FIG. 4 is a side view of the body support structure shown in FIG. 1, with an opposite side view being substantially a mirror image thereof.

[0017] FIG. 5 is a top view of the body support structure shown in FIG. 1.

[0018] FIG. 6 is a bottom view of the body support structure shown in FIG. 1.

[0019] FIG. 7 is a partial top view of the body support structure showing a tilt control.

[0020] FIG. 8 is a partial bottom perspective view of the body support structure.

[0021] FIG. 9 is a cross-sectional view of the body support structure taken along line 9-9 of FIG. 1.

[0022] FIG. 10 is a perspective view of one embodiment of a seat shell.

[0023] FIG. 11 is a bottom view of the seat shell shown in FIG. 10.

[0024] FIG. 12 is a partial rear perspective view of the body support structure.

[0025] FIG. 13 is a partial, cross-sectional view of the body support structure taken along line 13-13 of FIG. 1.

[0026] FIG. 14 is a partial, cross-sectional view of the body support structure taken along line 14-14 of Figure.

[0027] FIG. 15 is an exploded view of a portion of the seat and tilt control.

[0028] FIG. 16 is a partial cross-sectional view of a seat and / or backrest.

[0029] FIG. 17 is a partial side view of one embodiment of a back tilt mechanism.

[0030] FIG. 18 is a perspective view of one embodiment of an armrest.

[0031] FIG. 19 is a perspective view of an armrest support member body.

[0032] FIG. 20 is a perspective view of a carrier.

[0033] FIG. 21 is an exploded view of various armrest components.

[0034] FIGS. 22A-F are progressive views illustrating the assembly of the armrest carrier.

[0035] FIG. 23 is a cross-sectional view of a portion of the armrest without a pad.

[0036] FIG. 24 is a cross-sectional view of a portion of the armrest without a pad.

[0037] FIG. 25 is a bottom side of a portion of a carrier.

[0038] FIG. 26 is a partial cross-sectional view of a portion of a carrier secured to a body.

[0039] FIG. 27 is a partial perspective view of a portion of a carrier.

[0040] FIG. 28 is a partial cross-sectional view of a portion of an armrest without a pad member being shown.

[0041] FIG. 29 is a partial cross-sectional view of a portion of an armrest.

[0042] FIG. 30 is a partial bottom perspective of the body support structure shown in FIG. 1.

[0043] FIG. 31 is a partial plan view of the tilt control.

[0044] FIG. 32 is a partial plan view of the tilt control.

[0045] FIG. 33 is a partial side view showing the backrest and armrest connected to a seat bracket.

[0046] FIG. 34 is a partial front, perspective view of the backrest.

[0047] FIG. 35 is a partial cross-sectional view of the backrest and armrest connected to a seat bracket.

[0048] FIG. 36 is cross-sectional view of one embodiment of a tilt control.DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0049] It should be understood that the term “plurality,” as used herein, means two or more. As shown in FIGS. 1 and 14, the term “longitudinal,” as used herein, means of or relating to a length or lengthwise direction 2, for example a direction running from a top to bottom of a backrest 8, or a front to back of a seat 6, and vice versa (bottom to top and back to front), or along the length of a component. The term “lateral,” as used herein, means situated on, directed toward or running in a side-to-side direction 4 of the backrest 8 or seat 6. The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The term “fixed” means not moveable. The terms “first,”“second,” and so on, as used herein, are not meant to be assigned to a particular component or feature so designated, but rather are simply referring to such components and features in the numerical order as addressed, meaning that a component or feature designated as “first” may later be a “second” such component or feature, depending on the order in which it is referred. It should also be understood that designation of “first” and “second” does not necessarily mean that the two components, features or values so designated are different, meaning for example a first direction may be the same as a second direction, with each simply being applicable to different components or features. The terms “upper,”“lower,”“rear,”“front,”“fore,”“aft,”“vertical,”“horizontal,” and variations or derivatives thereof, refer to the orientations of the exemplary body support structure as shown in FIGS. 1 and 2 from the perspective of a person sitting thereon. The phrase “body support structure” refers to a structure that supports a body, including without limitation office furniture, home furniture, outdoor furniture and vehicular seating, including automotive, airline, marine and passenger train seating, and may include without limitation beds, chairs, sofas, stools, and other pieces of furniture or types of seating structures.

[0050] Referring to FIGS. 1-4, 7-9, 15, 31, 32, 35 and 36, the body support structure 10 includes the seat 6 and backrest 8 supported by a tilt control 12 (kinematic control system). The tilt control 12 includes a base member 14 or support, which may be configured as a tilt control housing. The base member 14 is coupled to and supported by a support column 16, which is supported in turn by a bottom base 18 configured with one or more floor engaging components 20, such as glides, casters or other types of feet. The bottom base 18 may be configured with multiple legs 22. Alternatively, the base support may be supported by other types of support platforms and legs, including a sled base, fixed legs (e.g., 2 or more), a pedestal support, rocker support or other suitable support platforms.

[0051] The tilt control also includes a tilt member 30 pivotally connected to the base member 14, for example with a pivot axle 24 defining a pivot axis 26. The tilt member 30 may be configured as a plate member. A spring 28 resists the recline tilting of the tilt member 30 relative to the base member 14 and returns the tilt member 30 from a reclined position to an upright, nominal position when not loaded by a user. In one embodiment, the spring 28 is configured as a compression spring acting between the base member 14 and the plate member 30 as the plate member 30 rotates about a laterally extending axis of the pivot axle 24. In one embodiment, an actuator lever 32 or rod extends laterally into the tilt control and is configured with an end portion 36 engaged with a button or actuator 38 at an upper end of the support column 16, which may be a pneumatic gas or hydraulic support column. The actuator lever 32 may be moved about a pivot, or alternatively rotated, to engage the actuator 38 such that the support column 16 may be depressed or extended to a desired height. For example, the lever 32 may be moved upwardly about a pivot to actuate the actuator 38 and allow for height adjustment. The lever 32 may also be moved in and out to effect a tilt lock action. A shroud or cover 33 may cover the upper portion of the support column and be attached to the base member 14 with fasteners as shown in FIG. 36.

[0052] As shown in FIGS. 7, 8 and 36, a seat bracket 40, configured as a pair of laterally spaced L-shaped brackets, is connected to the tilt member 30, for example with a plurality of fasteners 42. In another embodiment, shown in FIG. 15, the seat bracket may have side flanges 46 and a top plate 48, which is secured to the tilt member 30. The seat 6 includes a seat pan 44 coupled to the seat bracket 40, for example with the same fasteners. The seat pan 44 has an upper support member 50 defining a body support surface 52. A cushion 54 and upholstery 56 may be disposed on and supported by the upper support member 50. The upper support member may include a plurality of slots 60 formed therethrough in a front portion 64 of the support member to define a flex region 68. The slots 60, for example, may be laterally and longitudinally spaced, and may extend diagonally relative to a longitudinally extending center line 70. The front portion 64 of the upper support member 50, which may support the thighs of the user, may flex about the flex region 68 relative to a rear portion 66 when loaded by a user.

[0053] Referring to FIG. 15, the seat pan 44 further includes a side skirt 72, or peripheral annular flange, extending downwardly from the upper support member 50. The side skirt 72 may extend around the periphery of the upper support member. In one embodiment, the upper support member 50 and side skirt 72 are integrally formed as a single homogenous unit, formed for example of plastic. The side skirt 72 improves the overall rigidity of the seat pan and upper support member, while also providing a clean boundary line along a bottom edge 74 thereof, for example when wrapped with upholstery. Additional laterally extending slots 62 are formed along opposite sides of the upper support member, with the slots extending into the side skirt so as to define additional side flex regions 78. The slots 62 have terminal ends 76 in the side skirt, and do not extend to the lower edge 74 thereof, such that the continuous, uninterrupted bottom edge 74 is maintained around the periphery of the seat pan 44. The slots 62, defining the side flex regions 78, allow for the front portion 64 to flex or rotate downwardly relative to the rear portion 66, even when the seat pan is formed with a side skirt 72.

[0054] Referring to FIGS. 10, 11 and 15, the seat also includes a shell 80 disposed under and connected to the seat pan 44, wherein the tilt control 12 is disposed between the shell 80 and the seat pan 44. The shell 80 includes a plurality of tabs 82, shown as six, that engage openings 84 or catch portions formed at the edges of the openings in the seat pan 44. The rear portion 86 of the shell 80 may be further secured to the seat pan 44 with a plurality of fasteners 88.

[0055] In one embodiment, shown in FIG. 10, the shell 80 is secured to the seat pan 44 with a plurality of fasteners 90 configured as snaps, which are not exposed on, or require access from, a bottom side of the shell 80. Rather, the bottom surface of the shell has a smooth, uninterrupted surface.

[0056] An upper end 94 of the support column 16 extends through an opening 98 in the shell, such that it may be secured to the base member 14, for example with fasteners. The opening 98 may have an oval or obround shape, or may be circular. The shell 80 has a generally concave shape on the upper surface thereof, with a corresponding convex shape on the bottom surface thereof. A laterally extending curved recess 100 is formed on one side of the shell, and opens into the opening 98. The recess 100 has a downwardly facing concave surface 102, shown in FIGS. 6 and 10, and is shaped to provide clearance for the actuator lever 32. A slot 104, also opens into the opening 98, may be formed in the bottom of the concave surface to provide additional clearance for the actuator lever 32 as it pivots up and down.

[0057] The shell 80 also has a flex region 106, wherein a front portion 108 of the shell is flexible relative to a rear portion 110 of the shell about the flex region 106 as the front portion 64 of the seat pan 44 flexes relative to the rear portion 66 of the seat pan about the flex region 68. In one embodiment, the flex region 106 is defined at least in part by an elongated slot 112 extending laterally across the shell 80 between the front and rear portions 108, 110 of the shell. The slot may also extend longitudinally, for example along the sides thereof, and has an overall U-shape that wraps around the opening. The terminal ends 114 of the slot 112 may be turned laterally outwardly to the sides of the shell and define axes of rotation for the flex region. The rear portion 110 of the shell has an opening 116 formed therein, for example as a rectangular shape, which provides an open space for connecting an armrest support 292 and backrest 8 to the tilt control. Relief openings may be provided at the corners of the opening 116 to prevent fatigue cracking.

[0058] In one embodiment, the backrest 8 is connected to the tilt member 30 and is pivotable with the seat 6 relative to the base member 14. The backrest 8 is coupled to the seat brackets 40, for example with a plurality of fasteners 120 securing an intervening backrest bracket 118 to the seat brackets 40. Or the seat brackets 40 may be configured with a rear flange and are directly attached to the backrest 8. Referring to FIGS. 12, 13, 16, and 33-35, the backrest 8 includes a front shell 124 having a first peripheral edge 126 coupled to a rear shell 128 having a second peripheral edge 130. The peripheral edges 126, 130 may be configured as a lip turned rearwardly or forwardly respectively so as to form a nip 132, or gap, therebetween. The rear shell 128 may include a plurality of tabs 134 that are inserted through recessed openings 136 in the front shell and engage edge portions 138 thereof. A front cover 140 overlies the front shell 124 and is configured with a front peripheral edge portion 150. A rear cover 144 overlies the rear shell and is configured with a rear peripheral edge portion 152. The front and rear peripheral edge portions 150, 152 are wrapped around and disposed between the first and second peripheral edges 126, 130 by insertion through the nip 132 and define a peripheral seam 160 therebetween. The backrest 8 further includes a front cushion 142 disposed between the front cover 140 and the front surface of the front shell 124, and a rear cushion 146 disposed between the rear cover 144 and the rear shell 128. The front and rear shells both include a bottom portion 158 that extends forwardly under a rear portion of the seat. A bottom rim 162, or flange, of the bottom portion 158 is coupled to the backrest bracket 118 (or seat bracket 40), or a rear flange 180 thereof, for example with a plurality of fasteners 174.

[0059] Referring to FIG. 17, in an alternative embodiment, the backrest has a forwardly extending support 164 having a bracket 166 pivotally coupled to the tilt member with a pivot axle 168 about a horizontal pivot axis 170. A biasing member 172 is disposed between the support and the tilt member. The biasing member 172 biases the backrest 8 about the pivot axis 170 to an upright position. The biasing member may be configured as a spring, for example a compression spring, tension spring, leaf spring, and may be made of metal, or some other compressible and / or extensible material.

[0060] Referring to FIGS. 1-4, 13, 14 and 34, a pair of armrests 200 each includes an upper portion 202 connected to the backrest 8 and a lower portion 204 connected to at least one of the seat 6 and / or the tilt member 30, for example to the backrest bracket 118 or seat bracket 40. The upper portion 202 of the armrest includes a mounting plate 206 disposed between and connected to at least one of the front and rear shells 124, 128. In one embodiment, the mounting plate 206 is inserted through the nip / gap 132 and is disposed between the front and rear peripheral edge portions 126, 130 and between the first and second peripheral edges 150, 152 of the front and rear covers 140, 144. In one embodiment, the mounting plate 206 is connected to the front shell 124 with at least one fastener 208, for example three fasteners, shown as screws or bolts. In other embodiments, the mounting plate 206 may be secured with tabs and / or adhesives. The edge portions 126, 130 are spaced apart a greater amount at the interface with the mounting plate 206 as shown in FIGS. 33 and 13 as compared with the remaining portions of the backrest, wherein the edge portions 126, 130 form the nip and grip the cover edge portions 150, 152. At the interface with the mounting plate, the edge portions 150, 152 are clamped between the edge portions 126, 130 and opposite sides of the mouthing plate 206.

[0061] Referring to FIGS. 18-29, each armrest 200 includes a support member 220 and an arm pad 230 connected to the support member. The support member 220 includes a first track portion 222 defining a plurality (shown as three) of channels 224 each having a mouth 226 opening in a first translation direction 228 and a second track portion 232 defining at least one channel 234 having a mouth 236 opening in a second translation direction 238 opposite the first translation direction 228. The support member further includes a catch member 240.

[0062] The support member 220 may include an arm body 250, which may be a casting, for example made of metal such as aluminum. The track portions 222, 232 and catch member 240 may be coupled to the arm body. In one embodiment, the arm body 250 is configured with first, second and third cavities 251, 254, 256, wherein the first and second track portions 222, 232 and the catch member 240 are disposed respectively in the first, second and third cavities 251, 254, 256. The arm body may include at least one post 258 disposed in, and projecting outwardly from a bottom of, each of the first, second and third cavities 251, 254, 256. The track portions 222, 232 and catch member 240 have at least one opening 260, with the posts 258 inserted through respective ones of openings 260, and a plurality of push nuts 263 engaging at least one post 248 in each of the first, second and third cavities and securing the first and second track portions 222, 232 and catch member 249 in the first, second and third cavities 251, 254, 256. It should be understood that the tracks 222, 232 and catch member 240, may be formed as separate components, secured to the support for example with posts and push nuts, or may be integrally formed in the support, for example the body. The body may alternatively be made of plastic, for example injection molding.

[0063] In one embodiment, the first cavity 251 may have three posts 258 and the first track 222 three openings 260, while the second cavity 254 has two posts 258 and the second track 232 two openings 260, and the third cavity 256 has one post 248 and the catch member 240 one opening 260. In one embodiment, the first track portion 222 is formed or disposed on a horizontal component 280 of the support member, and is positioned in the cavity 251 formed in a horizontal portion of the arm body. The second track portion 232 is formed or disposed on a vertical component 282 of the support member and may be positioned in the second cavity 254 formed in a vertical portion of the arm body. The third cavity 256 is also formed or disposed on the vertical component 282, and disposed in a second cavity of the vertical portion, or a bottom curved end 286, of the arm body. The first and second track portions 222, 232 may be separate components, or integrally formed as a single component. Likewise, the first catch member 240 and first and second track components 222, 232 may be separate components, or formed integrally as a single component.

[0064] In one embodiment, the horizontal portion 280 of the arm body has a greater lateral width than a vertical thickness, while the vertical portion 282 has a greater longitudinal width than a latter thickness. In this embodiment, the horizontal and vertical portions 280, 282 are twisted 90 degrees relative to each other, and are joined by a corner apex 288. The mounting plate 206, having a vertical orientation, extends laterally inwardly from a rear end 291 of the horizontal portion 280. A lower mounting platform 292, having a horizontal orientation, extends laterally inwardly from the lower end 286 of the vertical portion. The mounting platform 292 is secured to the backrest bracket 118, seat bracket 40 and / or tilt member 30 with a plurality of fasteners. In this way, the armrest, seat and backrest all recline together about the pivot axis 26, except in an embodiment where the backrest 8 is further pivotally connected to the seat 6 as shown in FIG. 17.

[0065] The armrest 200 further includes an arm cap 250 having a carrier 252. The carrier 252 includes a first portion 255 having a plurality of first guides 257 insertable through the mouths 226 and moveable in the channels 224 from a first disengaged position to a first engaged position, a second portion 259 connected to the first portion and having a second guide 261 insertable through the second mouth 236 and moveable in the second channel 234 from a second disengaged position to a second engaged position, and a second catch member 262. In one embodiment, the first portion 255 is inserted or moved rearwardly relative to the portion 280 so as to engage the first track portion 222, while the second portion is thereafter inserted or moved downwardly relative to the portion 282 so as to engage the second track portion 232, with the catch member 262 thereafter being engaged with the catch member 240 to secure the arm cap 250. The first and second guides 257, 261 may be configured as L-shaped members, with a leg portion 269 insertable through the mouth and into the channel of the track portion, and a tab portion 264 engaging a surface 266 of the track portion between the track portion and the surface of the arm body. The first track 222 may include a flexible locking tab 270 positioned adjacent and spaced from the mouth 226 positioned closest to the apex 288. The locking tab 270 flexes as the carrier 252 and guide 257 are inserted into the mouth 226 and channel 224 in the first translational direction 228 to an installed position and then snaps into a locked position wherein an end 272 of the tab engages the guide 257, preventing the carrier from sliding relative to the track in the opposite direction. The guides 257 also engage an end 274 of a respective one of the channels 224 when moved to the installed position. The first and second catch members 240, 262 are engaged as the second guide 261 is moved in the second channel 234 to the second engaged position, with the guide 261 engaging an end 283 of the channel. In one embodiment, the second track portion 232, the second cavity 254 and second guide 261 may be omitted. In this embodiment, the first portion 255 is inserted or moved rearwardly relative to the portion 280 so as to engage the first track portion 222, with the catch member 262 thereafter being engaged with the catch member 240 to secure the arm cap 250.

[0066] The arm cap 250 further includes a pad member 290 coupled to an exterior (e.g., upper and front) surface of the carrier 252. The first and second portions of the carrier may be integrally formed as a single component. The second catch member may also be integrally formed with the first and second portions of the carrier are integrally formed as a single component. The arm body may include a recessed portion 300, wherein the carrier 252 is disposed in the recessed portion 300, such that an upper, exterior surface of the 262 is substantially flush with the exterior surface of the body at the edge of the recessed portion 300. In one embodiment, the pad member 290 may be configured as a cover, e.g., leather, that covers the exterior surface of the carrier and wraps around the carrier 252. The pad member 290 may be configured with peripheral side edges 293 disposed through a gap 294 between sides of the carrier and the arm body. The first and second cavities may be disposed or formed in a bottom of the recessed portion.

[0067] Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.

Examples

Embodiment Construction

[0049]It should be understood that the term “plurality,” as used herein, means two or more. As shown in FIGS. 1 and 14, the term “longitudinal,” as used herein, means of or relating to a length or lengthwise direction 2, for example a direction running from a top to bottom of a backrest 8, or a front to back of a seat 6, and vice versa (bottom to top and back to front), or along the length of a component. The term “lateral,” as used herein, means situated on, directed toward or running in a side-to-side direction 4 of the backrest 8 or seat 6. The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The term “fixed” means not moveable. The terms “first,”“second,” and so on, as used herein, are not meant to be assigned to a particular component or feature so designated, but rather are simply referring to such compone...

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 63 / 756,939, filed Feb. 11, 2025, the entire disclosure of which is hereby incorporated herein by reference.FIELD OF THE INVENTION

[0002] The present application relates generally to a body support structure such as a chair, an armrest for use with a body support structure, and to the methods for the use and assembly thereof.BACKGROUND

[0003] Body supporting structures, including for example, office chairs, vehicular and aircraft seating, sofas, beds and other pieces of furniture, are often configured with a relatively rigid seat and back shells or frames, which may support a cushion. While some deformation from the user's weight may be absorbed by the cushion, the underlying structure may not be capable of flexing and thereby providing additional adaptation and comfort. In addition, backrests on such chairs are typically not configured with a cushion on the rear side thereof, such that the surface may be susceptible to damage when impacted during use.

[0004] Furthermore, while some body support structures may be configured with armrests, such armrests may present a relatively hard surface to the user, for example when made with an exposed metal surface. It may be difficult to reliably configure such armrests with a pad to provide comfort to the user. Often, the pad is positioned above the armrest, and / or may be susceptible to snagging and / or severance from the armrest.SUMMARY

[0005] The present invention is defined by the following claims, and nothing in this section should be considered to be a limitation on those claims.

[0006] In one aspect, one embodiment of a body support structure includes a tilt control having a base member and a tilt member pivotally connected to the base member. A seat is connected to the tilt member and includes a seat pan having an upper support member and a side skirt extending downwardly from the upper support member. The seat pan includes a flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt, wherein a front portion of the seat pan is flexible relative to a rear portion of the seat pan about the flex region. A backrest is connected to the tilt member and is pivotable with the seat relative to the base. A pair of armrests each have an upper portion connected to the backrest and a lower portion connected to at least one of the seat and / or the tilt member.

[0007] In another aspect, one embodiment of a body support structure includes a tilt control and a seat connected to the tilt member. The seat includes a seat pan having an upper support member and a side skirt extending downwardly from the upper support member. The seat pan includes a first flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt. A front portion of the seat pan is flexible relative to a rear portion of the seat pan about the first flex region. A shell is disposed under, and connected to, the seat pan. The tilt control is disposed between the shell and the seat pan. The shell includes a second flex region, wherein a front portion of the shell is flexible relative to a rear portion of the shell about the second flex region as the front portion of the seat pan flexes relative to the rear portion of the seat pan about the first flex region.

[0008] In yet another aspect, one embodiment of a body support structure includes a seat and a backrest coupled to the seat. The backrest includes a front shell having a first peripheral edge, a rear shell coupled to the front shell and having a second peripheral edge, a front cover member overlying the front shell and having a first peripheral edge portion, a front cushion disposed between the front cover and the front shell, a rear cover overlying the rear shell and having a second peripheral edge portion, and a rear cushion disposed between the rear cover and the rear shell. The first and second peripheral edge portions are wrapped around and disposed between the first and second peripheral edges and define a peripheral seam therebetween.

[0009] In yet another aspect, an armrest includes a support member having a first track portion defining a first channel with a first mouth opening in a first translation direction, a second track portion defining a second channel with a second mouth opening in a second translation direction opposite the first translation direction, and a first catch member. An arm cap includes a carrier having a first portion with a first guide insertable through the first mouth and moveable in the first channel from a first disengaged position to a first engaged position, a second portion connected to the first portion and having a second guide insertable through the second mouth and moveable in the second channel from a second disengaged position to a second engaged position, and a second catch member. The first and second catch members are engaged as the second guide is moved in the second channel to the second engaged position.

[0010] Other methods of using and assembling the body support structure and armrest are also provided.

[0011] The various embodiments of body support structures, armrests and methods provide significant advantages over other body support structures, armrests, and methods for the manufacture, use and assembly thereof. For example, and without limitation, the seat pan provides a flexible support for a cushion and user, and when combined with a flexible shell, is capable of hiding the tilt control while providing flexure of the front portion of the seat relative to a rear portion thereof. The backrest also is provided with front and rear cushions, which improve the overall feel and appearance of the backrest, while also protecting the rear surface thereof. The armrest provides a unique support for an arm cap, which may be securely fixed to the support without tools. The support provides a robust attachment for the arm cap, which may be recessed in the support.

[0012] The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The various preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a front perspective view of one embodiment of a body support structure.

[0014] FIG. 2 is a front view of the body support structure shown in FIG. 1.

[0015] FIG. 3 is a rear view of the body support structure shown in FIG. 1.

[0016] FIG. 4 is a side view of the body support structure shown in FIG. 1, with an opposite side view being substantially a mirror image thereof.

[0017] FIG. 5 is a top view of the body support structure shown in FIG. 1.

[0018] FIG. 6 is a bottom view of the body support structure shown in FIG. 1.

[0019] FIG. 7 is a partial top view of the body support structure showing a tilt control.

[0020] FIG. 8 is a partial bottom perspective view of the body support structure.

[0021] FIG. 9 is a cross-sectional view of the body support structure taken along line 9-9 of FIG. 1.

[0022] FIG. 10 is a perspective view of one embodiment of a seat shell.

[0023] FIG. 11 is a bottom view of the seat shell shown in FIG. 10.

[0024] FIG. 12 is a partial rear perspective view of the body support structure.

[0025] FIG. 13 is a partial, cross-sectional view of the body support structure taken along line 13-13 of FIG. 1.

[0026] FIG. 14 is a partial, cross-sectional view of the body support structure taken along line 14-14 of Figure.

[0027] FIG. 15 is an exploded view of a portion of the seat and tilt control.

[0028] FIG. 16 is a partial cross-sectional view of a seat and / or backrest.

[0029] FIG. 17 is a partial side view of one embodiment of a back tilt mechanism.

[0030] FIG. 18 is a perspective view of one embodiment of an armrest.

[0031] FIG. 19 is a perspective view of an armrest support member body.

[0032] FIG. 20 is a perspective view of a carrier.

[0033] FIG. 21 is an exploded view of various armrest components.

[0034] FIGS. 22A-F are progressive views illustrating the assembly of the armrest carrier.

[0035] FIG. 23 is a cross-sectional view of a portion of the armrest without a pad.

[0036] FIG. 24 is a cross-sectional view of a portion of the armrest without a pad.

[0037] FIG. 25 is a bottom side of a portion of a carrier.

[0038] FIG. 26 is a partial cross-sectional view of a portion of a carrier secured to a body.

[0039] FIG. 27 is a partial perspective view of a portion of a carrier.

[0040] FIG. 28 is a partial cross-sectional view of a portion of an armrest without a pad member being shown.

[0041] FIG. 29 is a partial cross-sectional view of a portion of an armrest.

[0042] FIG. 30 is a partial bottom perspective of the body support structure shown in FIG. 1.

[0043] FIG. 31 is a partial plan view of the tilt control.

[0044] FIG. 32 is a partial plan view of the tilt control.

[0045] FIG. 33 is a partial side view showing the backrest and armrest connected to a seat bracket.

[0046] FIG. 34 is a partial front, perspective view of the backrest.

[0047] FIG. 35 is a partial cross-sectional view of the backrest and armrest connected to a seat bracket.

[0048] FIG. 36 is cross-sectional view of one embodiment of a tilt control.DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0049] It should be understood that the term “plurality,” as used herein, means two or more. As shown in FIGS. 1 and 14, the term “longitudinal,” as used herein, means of or relating to a length or lengthwise direction 2, for example a direction running from a top to bottom of a backrest 8, or a front to back of a seat 6, and vice versa (bottom to top and back to front), or along the length of a component. The term “lateral,” as used herein, means situated on, directed toward or running in a side-to-side direction 4 of the backrest 8 or seat 6. The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The term “fixed” means not moveable. The terms “first,”“second,” and so on, as used herein, are not meant to be assigned to a particular component or feature so designated, but rather are simply referring to such components and features in the numerical order as addressed, meaning that a component or feature designated as “first” may later be a “second” such component or feature, depending on the order in which it is referred. It should also be understood that designation of “first” and “second” does not necessarily mean that the two components, features or values so designated are different, meaning for example a first direction may be the same as a second direction, with each simply being applicable to different components or features. The terms “upper,”“lower,”“rear,”“front,”“fore,”“aft,”“vertical,”“horizontal,” and variations or derivatives thereof, refer to the orientations of the exemplary body support structure as shown in FIGS. 1 and 2 from the perspective of a person sitting thereon. The phrase “body support structure” refers to a structure that supports a body, including without limitation office furniture, home furniture, outdoor furniture and vehicular seating, including automotive, airline, marine and passenger train seating, and may include without limitation beds, chairs, sofas, stools, and other pieces of furniture or types of seating structures.

[0050] Referring to FIGS. 1-4, 7-9, 15, 31, 32, 35 and 36, the body support structure 10 includes the seat 6 and backrest 8 supported by a tilt control 12 (kinematic control system). The tilt control 12 includes a base member 14 or support, which may be configured as a tilt control housing. The base member 14 is coupled to and supported by a support column 16, which is supported in turn by a bottom base 18 configured with one or more floor engaging components 20, such as glides, casters or other types of feet. The bottom base 18 may be configured with multiple legs 22. Alternatively, the base support may be supported by other types of support platforms and legs, including a sled base, fixed legs (e.g., 2 or more), a pedestal support, rocker support or other suitable support platforms.

[0051] The tilt control also includes a tilt member 30 pivotally connected to the base member 14, for example with a pivot axle 24 defining a pivot axis 26. The tilt member 30 may be configured as a plate member. A spring 28 resists the recline tilting of the tilt member 30 relative to the base member 14 and returns the tilt member 30 from a reclined position to an upright, nominal position when not loaded by a user. In one embodiment, the spring 28 is configured as a compression spring acting between the base member 14 and the plate member 30 as the plate member 30 rotates about a laterally extending axis of the pivot axle 24. In one embodiment, an actuator lever 32 or rod extends laterally into the tilt control and is configured with an end portion 36 engaged with a button or actuator 38 at an upper end of the support column 16, which may be a pneumatic gas or hydraulic support column. The actuator lever 32 may be moved about a pivot, or alternatively rotated, to engage the actuator 38 such that the support column 16 may be depressed or extended to a desired height. For example, the lever 32 may be moved upwardly about a pivot to actuate the actuator 38 and allow for height adjustment. The lever 32 may also be moved in and out to effect a tilt lock action. A shroud or cover 33 may cover the upper portion of the support column and be attached to the base member 14 with fasteners as shown in FIG. 36.

[0052] As shown in FIGS. 7, 8 and 36, a seat bracket 40, configured as a pair of laterally spaced L-shaped brackets, is connected to the tilt member 30, for example with a plurality of fasteners 42. In another embodiment, shown in FIG. 15, the seat bracket may have side flanges 46 and a top plate 48, which is secured to the tilt member 30. The seat 6 includes a seat pan 44 coupled to the seat bracket 40, for example with the same fasteners. The seat pan 44 has an upper support member 50 defining a body support surface 52. A cushion 54 and upholstery 56 may be disposed on and supported by the upper support member 50. The upper support member may include a plurality of slots 60 formed therethrough in a front portion 64 of the support member to define a flex region 68. The slots 60, for example, may be laterally and longitudinally spaced, and may extend diagonally relative to a longitudinally extending center line 70. The front portion 64 of the upper support member 50, which may support the thighs of the user, may flex about the flex region 68 relative to a rear portion 66 when loaded by a user.

[0053] Referring to FIG. 15, the seat pan 44 further includes a side skirt 72, or peripheral annular flange, extending downwardly from the upper support member 50. The side skirt 72 may extend around the periphery of the upper support member. In one embodiment, the upper support member 50 and side skirt 72 are integrally formed as a single homogenous unit, formed for example of plastic. The side skirt 72 improves the overall rigidity of the seat pan and upper support member, while also providing a clean boundary line along a bottom edge 74 thereof, for example when wrapped with upholstery. Additional laterally extending slots 62 are formed along opposite sides of the upper support member, with the slots extending into the side skirt so as to define additional side flex regions 78. The slots 62 have terminal ends 76 in the side skirt, and do not extend to the lower edge 74 thereof, such that the continuous, uninterrupted bottom edge 74 is maintained around the periphery of the seat pan 44. The slots 62, defining the side flex regions 78, allow for the front portion 64 to flex or rotate downwardly relative to the rear portion 66, even when the seat pan is formed with a side skirt 72.

[0054] Referring to FIGS. 10, 11 and 15, the seat also includes a shell 80 disposed under and connected to the seat pan 44, wherein the tilt control 12 is disposed between the shell 80 and the seat pan 44. The shell 80 includes a plurality of tabs 82, shown as six, that engage openings 84 or catch portions formed at the edges of the openings in the seat pan 44. The rear portion 86 of the shell 80 may be further secured to the seat pan 44 with a plurality of fasteners 88.

[0055] In one embodiment, shown in FIG. 10, the shell 80 is secured to the seat pan 44 with a plurality of fasteners 90 configured as snaps, which are not exposed on, or require access from, a bottom side of the shell 80. Rather, the bottom surface of the shell has a smooth, uninterrupted surface.

[0056] An upper end 94 of the support column 16 extends through an opening 98 in the shell, such that it may be secured to the base member 14, for example with fasteners. The opening 98 may have an oval or obround shape, or may be circular. The shell 80 has a generally concave shape on the upper surface thereof, with a corresponding convex shape on the bottom surface thereof. A laterally extending curved recess 100 is formed on one side of the shell, and opens into the opening 98. The recess 100 has a downwardly facing concave surface 102, shown in FIGS. 6 and 10, and is shaped to provide clearance for the actuator lever 32. A slot 104, also opens into the opening 98, may be formed in the bottom of the concave surface to provide additional clearance for the actuator lever 32 as it pivots up and down.

[0057] The shell 80 also has a flex region 106, wherein a front portion 108 of the shell is flexible relative to a rear portion 110 of the shell about the flex region 106 as the front portion 64 of the seat pan 44 flexes relative to the rear portion 66 of the seat pan about the flex region 68. In one embodiment, the flex region 106 is defined at least in part by an elongated slot 112 extending laterally across the shell 80 between the front and rear portions 108, 110 of the shell. The slot may also extend longitudinally, for example along the sides thereof, and has an overall U-shape that wraps around the opening. The terminal ends 114 of the slot 112 may be turned laterally outwardly to the sides of the shell and define axes of rotation for the flex region. The rear portion 110 of the shell has an opening 116 formed therein, for example as a rectangular shape, which provides an open space for connecting an armrest support 292 and backrest 8 to the tilt control. Relief openings may be provided at the corners of the opening 116 to prevent fatigue cracking.

[0058] In one embodiment, the backrest 8 is connected to the tilt member 30 and is pivotable with the seat 6 relative to the base member 14. The backrest 8 is coupled to the seat brackets 40, for example with a plurality of fasteners 120 securing an intervening backrest bracket 118 to the seat brackets 40. Or the seat brackets 40 may be configured with a rear flange and are directly attached to the backrest 8. Referring to FIGS. 12, 13, 16, and 33-35, the backrest 8 includes a front shell 124 having a first peripheral edge 126 coupled to a rear shell 128 having a second peripheral edge 130. The peripheral edges 126, 130 may be configured as a lip turned rearwardly or forwardly respectively so as to form a nip 132, or gap, therebetween. The rear shell 128 may include a plurality of tabs 134 that are inserted through recessed openings 136 in the front shell and engage edge portions 138 thereof. A front cover 140 overlies the front shell 124 and is configured with a front peripheral edge portion 150. A rear cover 144 overlies the rear shell and is configured with a rear peripheral edge portion 152. The front and rear peripheral edge portions 150, 152 are wrapped around and disposed between the first and second peripheral edges 126, 130 by insertion through the nip 132 and define a peripheral seam 160 therebetween. The backrest 8 further includes a front cushion 142 disposed between the front cover 140 and the front surface of the front shell 124, and a rear cushion 146 disposed between the rear cover 144 and the rear shell 128. The front and rear shells both include a bottom portion 158 that extends forwardly under a rear portion of the seat. A bottom rim 162, or flange, of the bottom portion 158 is coupled to the backrest bracket 118 (or seat bracket 40), or a rear flange 180 thereof, for example with a plurality of fasteners 174.

[0059] Referring to FIG. 17, in an alternative embodiment, the backrest has a forwardly extending support 164 having a bracket 166 pivotally coupled to the tilt member with a pivot axle 168 about a horizontal pivot axis 170. A biasing member 172 is disposed between the support and the tilt member. The biasing member 172 biases the backrest 8 about the pivot axis 170 to an upright position. The biasing member may be configured as a spring, for example a compression spring, tension spring, leaf spring, and may be made of metal, or some other compressible and / or extensible material.

[0060] Referring to FIGS. 1-4, 13, 14 and 34, a pair of armrests 200 each includes an upper portion 202 connected to the backrest 8 and a lower portion 204 connected to at least one of the seat 6 and / or the tilt member 30, for example to the backrest bracket 118 or seat bracket 40. The upper portion 202 of the armrest includes a mounting plate 206 disposed between and connected to at least one of the front and rear shells 124, 128. In one embodiment, the mounting plate 206 is inserted through the nip / gap 132 and is disposed between the front and rear peripheral edge portions 126, 130 and between the first and second peripheral edges 150, 152 of the front and rear covers 140, 144. In one embodiment, the mounting plate 206 is connected to the front shell 124 with at least one fastener 208, for example three fasteners, shown as screws or bolts. In other embodiments, the mounting plate 206 may be secured with tabs and / or adhesives. The edge portions 126, 130 are spaced apart a greater amount at the interface with the mounting plate 206 as shown in FIGS. 33 and 13 as compared with the remaining portions of the backrest, wherein the edge portions 126, 130 form the nip and grip the cover edge portions 150, 152. At the interface with the mounting plate, the edge portions 150, 152 are clamped between the edge portions 126, 130 and opposite sides of the mouthing plate 206.

[0061] Referring to FIGS. 18-29, each armrest 200 includes a support member 220 and an arm pad 230 connected to the support member. The support member 220 includes a first track portion 222 defining a plurality (shown as three) of channels 224 each having a mouth 226 opening in a first translation direction 228 and a second track portion 232 defining at least one channel 234 having a mouth 236 opening in a second translation direction 238 opposite the first translation direction 228. The support member further includes a catch member 240.

[0062] The support member 220 may include an arm body 250, which may be a casting, for example made of metal such as aluminum. The track portions 222, 232 and catch member 240 may be coupled to the arm body. In one embodiment, the arm body 250 is configured with first, second and third cavities 251, 254, 256, wherein the first and second track portions 222, 232 and the catch member 240 are disposed respectively in the first, second and third cavities 251, 254, 256. The arm body may include at least one post 258 disposed in, and projecting outwardly from a bottom of, each of the first, second and third cavities 251, 254, 256. The track portions 222, 232 and catch member 240 have at least one opening 260, with the posts 258 inserted through respective ones of openings 260, and a plurality of push nuts 263 engaging at least one post 248 in each of the first, second and third cavities and securing the first and second track portions 222, 232 and catch member 249 in the first, second and third cavities 251, 254, 256. It should be understood that the tracks 222, 232 and catch member 240, may be formed as separate components, secured to the support for example with posts and push nuts, or may be integrally formed in the support, for example the body. The body may alternatively be made of plastic, for example injection molding.

[0063] In one embodiment, the first cavity 251 may have three posts 258 and the first track 222 three openings 260, while the second cavity 254 has two posts 258 and the second track 232 two openings 260, and the third cavity 256 has one post 248 and the catch member 240 one opening 260. In one embodiment, the first track portion 222 is formed or disposed on a horizontal component 280 of the support member, and is positioned in the cavity 251 formed in a horizontal portion of the arm body. The second track portion 232 is formed or disposed on a vertical component 282 of the support member and may be positioned in the second cavity 254 formed in a vertical portion of the arm body. The third cavity 256 is also formed or disposed on the vertical component 282, and disposed in a second cavity of the vertical portion, or a bottom curved end 286, of the arm body. The first and second track portions 222, 232 may be separate components, or integrally formed as a single component. Likewise, the first catch member 240 and first and second track components 222, 232 may be separate components, or formed integrally as a single component.

[0064] In one embodiment, the horizontal portion 280 of the arm body has a greater lateral width than a vertical thickness, while the vertical portion 282 has a greater longitudinal width than a latter thickness. In this embodiment, the horizontal and vertical portions 280, 282 are twisted 90 degrees relative to each other, and are joined by a corner apex 288. The mounting plate 206, having a vertical orientation, extends laterally inwardly from a rear end 291 of the horizontal portion 280. A lower mounting platform 292, having a horizontal orientation, extends laterally inwardly from the lower end 286 of the vertical portion. The mounting platform 292 is secured to the backrest bracket 118, seat bracket 40 and / or tilt member 30 with a plurality of fasteners. In this way, the armrest, seat and backrest all recline together about the pivot axis 26, except in an embodiment where the backrest 8 is further pivotally connected to the seat 6 as shown in FIG. 17.

[0065] The armrest 200 further includes an arm cap 250 having a carrier 252. The carrier 252 includes a first portion 255 having a plurality of first guides 257 insertable through the mouths 226 and moveable in the channels 224 from a first disengaged position to a first engaged position, a second portion 259 connected to the first portion and having a second guide 261 insertable through the second mouth 236 and moveable in the second channel 234 from a second disengaged position to a second engaged position, and a second catch member 262. In one embodiment, the first portion 255 is inserted or moved rearwardly relative to the portion 280 so as to engage the first track portion 222, while the second portion is thereafter inserted or moved downwardly relative to the portion 282 so as to engage the second track portion 232, with the catch member 262 thereafter being engaged with the catch member 240 to secure the arm cap 250. The first and second guides 257, 261 may be configured as L-shaped members, with a leg portion 269 insertable through the mouth and into the channel of the track portion, and a tab portion 264 engaging a surface 266 of the track portion between the track portion and the surface of the arm body. The first track 222 may include a flexible locking tab 270 positioned adjacent and spaced from the mouth 226 positioned closest to the apex 288. The locking tab 270 flexes as the carrier 252 and guide 257 are inserted into the mouth 226 and channel 224 in the first translational direction 228 to an installed position and then snaps into a locked position wherein an end 272 of the tab engages the guide 257, preventing the carrier from sliding relative to the track in the opposite direction. The guides 257 also engage an end 274 of a respective one of the channels 224 when moved to the installed position. The first and second catch members 240, 262 are engaged as the second guide 261 is moved in the second channel 234 to the second engaged position, with the guide 261 engaging an end 283 of the channel. In one embodiment, the second track portion 232, the second cavity 254 and second guide 261 may be omitted. In this embodiment, the first portion 255 is inserted or moved rearwardly relative to the portion 280 so as to engage the first track portion 222, with the catch member 262 thereafter being engaged with the catch member 240 to secure the arm cap 250.

[0066] The arm cap 250 further includes a pad member 290 coupled to an exterior (e.g., upper and front) surface of the carrier 252. The first and second portions of the carrier may be integrally formed as a single component. The second catch member may also be integrally formed with the first and second portions of the carrier are integrally formed as a single component. The arm body may include a recessed portion 300, wherein the carrier 252 is disposed in the recessed portion 300, such that an upper, exterior surface of the 262 is substantially flush with the exterior surface of the body at the edge of the recessed portion 300. In one embodiment, the pad member 290 may be configured as a cover, e.g., leather, that covers the exterior surface of the carrier and wraps around the carrier 252. The pad member 290 may be configured with peripheral side edges 293 disposed through a gap 294 between sides of the carrier and the arm body. The first and second cavities may be disposed or formed in a bottom of the recessed portion.

[0067] Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.

Examples

Embodiment Construction

[0049]It should be understood that the term “plurality,” as used herein, means two or more. As shown in FIGS. 1 and 14, the term “longitudinal,” as used herein, means of or relating to a length or lengthwise direction 2, for example a direction running from a top to bottom of a backrest 8, or a front to back of a seat 6, and vice versa (bottom to top and back to front), or along the length of a component. The term “lateral,” as used herein, means situated on, directed toward or running in a side-to-side direction 4 of the backrest 8 or seat 6. The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The term “fixed” means not moveable. The terms “first,”“second,” and so on, as used herein, are not meant to be assigned to a particular component or feature so designated, but rather are simply referring to such compone...

Claims

1. A body support structure comprising:a tilt control comprising a base member and a tilt member pivotally connected to the base member;a seat connected to the tilt member, wherein the seat comprises a seat pan comprising an upper support member and a side skirt extending downwardly from the upper support member, wherein the seat pan comprises a flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt, wherein a front portion of the seat pan is flexible relative to a rear portion of the seat pan about the flex region;a backrest connected to the tilt member, wherein the backrest is pivotable with the seat relative to the base; anda pair of armrests, each armrest having an upper portion connected to the backrest and a lower portion connected to at least one of the seat and / or the tilt member.

2. The body support structure of claim 1 wherein the backrest comprises a front shell having a first peripheral edge coupled to a rear shell having a second peripheral edge, a front cover member overlying the front shell and comprising a front peripheral edge portion and a rear cover overlying the rear shell and comprising a rear peripheral edge portion, wherein the front and rear peripheral edge portions are wrapped around and disposed between the first and second peripheral edges and define a peripheral seam therebetween.

3. The body support structure of claim 2 wherein the armrest comprises a mounting plate disposed between and connected to at least one of the front and rear shells.

4. The body support structure of claim 3 wherein the mounting plate is disposed between the front and rear peripheral edge portions and between the first and second peripheral edges.

5. The body support structure of claim 3 wherein the mounting plate is connected to the front shell with at least one fastener.

6. The body support structure of claim 2 further comprising a front cushion disposed between the front cover and the front shell.

7. The body support structure of claim 6 further comprising a rear cushion disposed between the rear cover and the rear shell.

8. The body support structure of claim 1 wherein the backrest comprises a forwardly extending support pivotally coupled to the tilt member about a horizontal pivot axis, and a biasing member disposed between the support and the tilt member, wherein the biasing member biases the backrest about the pivot axis to an upright position.

9. The body support structure of claim 1 wherein the seat further comprises a shell disposed under and connected to the seat pan, wherein the tilt control is disposed between the shell and the seat pan, wherein the flex region comprises a first flex region, and wherein the shell comprises an elongated slot defining a second flex region, wherein a front portion of the shell is flexible relative to a rear portion of the shell as the front portion of the seat pan flexes relative to the rear portion of the seat pan about the flex region.

10. The body support structure of claim 1 wherein the armrest comprises a support member and an arm pad connected to the support member.

11. A body support structure comprising:a tilt control;a seat connected to the tilt member, wherein the seat comprises:a seat pan comprising an upper support member and a side skirt extending downwardly from the upper support member, wherein the seat pan comprises a first flex region defined at least in part by a plurality of slots formed in the upper support member and the side skirt, wherein a front portion of the seat pan is flexible relative to a rear portion of the seat pan about the first flex region; anda shell disposed under and connected to the seat pan, wherein the tilt control is disposed between the shell and the seat pan, wherein the shell comprises a second flex region, wherein a front portion of the shell is flexible relative to a rear portion of the shell about the second flex region as the front portion of the seat pan flexes relative to the rear portion of the seat pan about the first flex region.

12. The body support structure of claim 11 wherein the second flex region is defined at least in part by an elongated slot extending laterally across the shell between the front and rear portions of the shell.

13. A body support structure comprising:a seat;a backrest coupled to the seat, wherein the backrest comprises:a front shell comprising a first peripheral edge;a rear shell coupled to the front shell and comprising a second peripheral edge,a front cover member overlying the front shell and comprising a first peripheral edge portion;a front cushion disposed between the front cover and the front shell;a rear cover overlying the rear shell and comprising a second peripheral edge portion; anda rear cushion disposed between the rear cover and the rear shell;wherein the first and second peripheral edge portions are wrapped around and disposed between the first and second peripheral edges and define a peripheral seam therebetween.

14. The body support structure of claim 13 further comprising an armrest having a mounting plate disposed between and connected to at least one of the front and rear shells.

15. The body support structure of claim 14 wherein the mounting plate is disposed between the first and second peripheral edge portions and between the first and second peripheral edges.

16. The body support structure of claim 14 wherein the mounting plate is connected to the front shell with at least one fastener.

17. An armrest comprising:a support member comprising:a first track portion defining a first channel having a first mouth opening in a first translation direction;a second track portion defining a second channel having a second mouth opening in a second translation direction opposite the first translation direction; anda first catch member; andan arm cap comprising a carrier, wherein the carrier comprises:a first portion having a first guide insertable through the first mouth and moveable in the first channel from a first disengaged position to a first engaged position;a second portion connected to the first portion and having a second guide insertable through the second mouth and moveable in the second channel from a second disengaged position to a second engaged position; anda second catch member, wherein the first and second catch members are engaged as the second guide is moved in the second channel to the second engaged position.

18. The armrest of claim 17 wherein the support member comprises an arm body, and wherein the first and second track portions and first catch member are coupled to the body.

19. The armrest of claim 18 wherein the arm body comprises a casting.

20. The armrest of claim 18 wherein the arm body comprises first and second cavities, wherein the first and second track portions are disposed respectively in the first and second cavities.

21. The armrest of claim 20 wherein the arm body comprises at least one post disposed in each of the first and second cavities.

22. The armrest of claim 21 further comprising first and second push nuts engaging the at least one post in each of the first and second cavities and securing the first and second track portions in the first and second cavities.

23. The armrest of claim 17 wherein the arm cap further comprises a pad member coupled to an exterior surface of the carrier.

24. The armrest of claim 17 wherein the first track portion is formed on a horizontal component of the support member and the second track portion is formed on a vertical component of the support member.

25. The armrest of claim 17 wherein the first and second track portions are separate components.

26. The armrest of claim 25 wherein the first catch member and first and second track components are separate components.

27. The armrest of claim 25 wherein the first and second portions of the carrier are integrally formed as a single component.

28. The armrest of claim 27 wherein the second catch member and the first and second portions of the carrier are integrally formed as a single component.

29. The armrest of claim 23 wherein the arm body comprises a recessed portion, wherein the carrier is disposed in the recess portion.

30. The armrest of claim 29 wherein the pad member wraps around the carrier and comprises peripheral side edges disposed between sides of the carrier and the arm body.

31. The armrest of claim 29 wherein the first and second channels are disposed in a bottom of the recessed portion.

Images