U.S. patent application number 13/089773 was filed with the patent office on 2011-10-06 for multilayer load bearing structure.
Invention is credited to John F. Aldrich, Ryan S. Brill, Christopher C. Hill, Jason Holt, Timothy Hoogland, Andrew J. Kurrasch, Douglas M. VanDeRiet, Jeffrey A. Weber.
Application Number | 20110241270 13/089773 |
Document ID | / |
Family ID | 34555913 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110241270 |
Kind Code |
A1 |
VanDeRiet; Douglas M. ; et
al. |
October 6, 2011 |
MULTILAYER LOAD BEARING STRUCTURE
Abstract
Support elements and support structures form the basis of
ergonomic body supports for chairs, mattresses and other
structures. The support elements may be individually designed
according to their location and body support function. Thus, the
structures that include the support elements may provide
point-tailored support for any part of the body to enhance comfort,
fit, and proper anatomical support.
Inventors: |
VanDeRiet; Douglas M.;
(Holland, MI) ; Hill; Christopher C.; (Holland,
MI) ; Kurrasch; Andrew J.; (Saugatuck, MI) ;
Aldrich; John F.; (Grandville, MI) ; Hoogland;
Timothy; (Zeeland, MI) ; Weber; Jeffrey A.;
(Minneapolis, MN) ; Holt; Jason; (Minneapolis,
MN) ; Brill; Ryan S.; (Allendale, MI) |
Family ID: |
34555913 |
Appl. No.: |
13/089773 |
Filed: |
April 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11645234 |
Dec 21, 2006 |
7931257 |
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13089773 |
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10972153 |
Oct 22, 2004 |
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11645234 |
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60513775 |
Oct 23, 2003 |
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60599201 |
Aug 5, 2004 |
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Current U.S.
Class: |
267/142 |
Current CPC
Class: |
A47C 7/027 20130101;
A47C 23/002 20130101; F16F 1/025 20130101; A47C 7/282 20130101;
A47C 23/05 20130101; A47C 7/029 20180801 |
Class at
Publication: |
267/142 |
International
Class: |
A47C 27/00 20060101
A47C027/00; F16F 3/00 20060101 F16F003/00 |
Claims
1. A body support structure comprising: an upper support layer
comprising a first plurality of peaks and a first plurality of
valleys; a lower base layer comprising a second plurality of peaks
and a second plurality of valleys, wherein the first plurality of
peaks is vertically aligned with the second plurality of valleys;
and an intermediate layer comprising an elastomeric material
disposed between the upper support layer and the lower base
layer.
2. The body support structure of claim 1 wherein the intermediate
layer is engaged by the first and second plurality of peaks.
3. The body support structure of claim 1 wherein the upper support
layer and the lower base layer are moveable from an unloaded
condition toward each other to a loaded condition in response to an
applied load, with the first plurality of peaks moveable toward and
into said second plurality of valleys as the upper support layer
and lower base layer are moved to the loaded condition, and wherein
the intermediate layer is deformable in response to the relative
movement of said upper support layer and said lower base layer.
4. The body support structure of claim 3 wherein the intermediate
layer is substantially planar when the upper support layer and
lower base layer are in the unloaded condition.
5. The body support structure of claim 1 wherein at least some
adjacent ones of the first plurality of peaks are separated by a
first distance and at least some adjacent others of the first
plurality of peaks are separated by a second distance different
than the first distance.
6. The body support structure of claim 5 wherein at least some of
the second plurality of valleys underlying the at least some of the
first plurality of peaks are separated by the first distance and at
least some others of the second plurality of valleys underlying the
at least some others of the first plurality of peaks are separated
by the second distance.
7. The body support structure of claim 1 wherein at least one of
the first plurality of peaks has a first height and at least one of
the second plurality of valleys underlying the at least one of the
first plurality of peaks has a first depth, the first height and
the first depth providing a pre-selected travel distance for the at
least one of the first plurality of peaks relative to the at least
one of the second plurality of valleys.
8. The body support structure of claim 7 wherein at least another
of the first plurality of peaks has a second height different than
the first height and at least another of the second plurality of
valleys underlying the at least another of the first plurality of
peaks has a second depth different than the first depth.
9. A body support structure comprising: an upper support layer
comprising a first plurality of peaks and a first plurality of
valleys, wherein at least some adjacent ones of the first plurality
of peaks are spaced apart a first distance and at least some other
adjacent ones of the first plurality of peaks are spaced apart a
second distance different than the first distance; a lower base
layer comprising a second plurality of peaks and a second plurality
of valleys, wherein the first plurality of peaks is vertically
aligned with the second plurality of valleys, wherein at least some
adjacent ones of the second plurality of valleys underlying the at
least some adjacent ones of the first plurality of peaks are spaced
apart the first distance, and at least some other adjacent ones of
the second plurality of valleys underlying the at least some other
adjacent ones of the first plurality of peaks are spaced apart the
second distance; and an intermediate layer comprising an
elastomeric material disposed between the upper support layer and
the lower base layer.
10. The body support structure of claim 9 wherein the intermediate
layer is engaged by the first and second plurality of peaks.
11. The body support structure of claim 9 wherein the upper support
layer and the lower base layer are moveable from an unloaded
condition toward each other to a loaded condition in response to an
applied load, with the first plurality of peaks moveable toward and
into said second plurality of valleys as the upper support layer
and lower base layer are moved to the loaded condition, and wherein
the intermediate layer is deformable in response to the relative
movement of said upper support layer and said lower base layer.
12. The body support structure of claim 11 wherein the intermediate
layer is substantially planar when the upper support layer and
lower base layer are in the unloaded condition.
13. A method of supporting a user on a body support structure
comprising: applying a body load to a body support structure and
thereby applying a load to an upper support layer comprising a
first plurality of peaks and a first plurality of valleys; applying
an applied load with the first plurality of peaks to a first side
of an intermediate layer comprising an elastomeric material;
applying a reactive load to an opposite side of the intermediate
layer with a second plurality of peaks configured on a lower base
layer; moving the first plurality of peaks toward the second
plurality of valleys; and deforming the intermediate layer between
the upper support layer and the lower base layer, wherein the lower
base layer further comprises a second plurality of valleys, wherein
the first plurality of peaks is vertically aligned with the second
plurality of valleys and the second plurality of peaks is
vertically aligned with the first plurality of valleys.
14. The method of claim 13 wherein the intermediate layer is
substantially planar prior to the applying of the body load.
15. The method of claim 13 wherein at least some adjacent ones of
the first plurality of peaks are separated by a first distance and
at least some adjacent others of the first plurality of peaks are
separated by a second distance different than the first
distance.
16. The method of claim 15 wherein at least some of the second
plurality of valleys underlying the at least some of the first
plurality of peaks are separated by the first distance and at least
some others of the second plurality of valleys underlying the at
least some others of the first plurality of peaks are separated by
the second distance.
17. The method of claim 13 wherein at least one of the first
plurality of peaks has a first height and at least one of the
second plurality of valleys underlying the at least one of the
first plurality of peaks has a first depth, the first height and
the first depth providing a pre-selected travel distance for the at
least one of the first plurality of peaks relative to the at least
one of the second plurality of valleys.
18. The method of claim 17 wherein at least another of the first
plurality of peaks has a second height different than the first
height and at least another of the second plurality of valleys
underlying the at least another of the first plurality of peaks has
a second depth different than the first depth.
Description
PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/645,234, filed Dec. 21, 2006, titled
MULTILAYER LOAD BEARING STRUCTURE, which is a continuation of U.S.
patent application Ser. No. 10/972,153, titled PIXELATED SUPPORT
STRUCTURES AND ELEMENTS, filed Oct. 22, 2004, which claims the
benefit of U.S. Provisional Patent Application No. 60/513,775,
titled PIXELATED SUPPORT STRUCTURES AND ELEMENTS, filed Oct. 23,
2003, and U.S. Provisional Patent Application No. 60/599,201,
titled PIXELATED SUPPORT STRUCTURES AND ELEMENTS, filed Aug. 5,
2004, the entire disclosures of which are hereby incorporated
herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to load bearing structures. In
particular, the present invention relates to multiple layer load
bearing structures.
[0004] 2. Background Information
[0005] People spend a significant number of hours sitting each day.
Regardless of the task being performed, or the leisure activity
being pursued, support structures that properly support the body
not only make the individual more comfortable, but may also provide
significant health benefits. For this reason, extensive research
and development has occurred and continues to occur into support
structures for chairs, mattresses, and so forth.
[0006] In the past, for example, bed systems have encompassed a
wide range of designs, ranging from simple cushions to complex
arrangements of individual bearing elements. These past designs
have been successful to varying degrees, but do not always provide
the appropriate level of support for each part of the body. Thus,
while some progress has been made in providing ergonomic body
support structures, there remains a need for improved support
structures that provide excellent fit and comfort, as well as
healthy support for the body, across a wide range of individual
body types.
BRIEF SUMMARY
[0007] Structural components consistent with the present invention
provide pixelated body support elements as well as pixelated body
support structures incorporating the pixelated body support
elements. The support structures may be employed in the design of a
backrest or seat for a chair, as examples, or may be incorporated
into any other body support device (e.g., a mattress or bed
system). The pixelated support elements may be independently
designed according to their selected or assigned location in the
support structure. The resultant design may thereby provide
point-tailored support for the body that varies according to
support most beneficial or desirable for any given body region.
[0008] In one implementation, a pixelated support element for a
pixelated support structure may include a spring cradle that
includes a cradle base and a spring support structure. In addition,
the pixelated support element includes a spring element at least
partially disposed in the spring cradle. The spring cradle may then
be designed to impart a selected spring stiffness to the spring
element.
[0009] In another implementation, the pixelated support element may
include an upper support layer defining a series of peaks and
valleys and a lower base layer also defining a series of peaks and
valleys. Additionally, an elastomer material is disposed between
the upper support layer and the lower base layer, and imparts a
selected degree of stiffness to the pixelated support element.
[0010] Similarly, a pixelated support structure consistent with the
present invention may include a support spine, a spline disposed
laterally across the support spine, and cantilever branches
extending outwardly from the spline. Each cantilever branch may
include a terminal end connected to the spline, a support end
opposite the terminal end, and a load bearing element connected to
the support end. Additionally, a bridging connection is provided
between pixelated support elements, thereby connecting sets of load
bearing elements together into larger groups (e.g., a 2.times.2 or
4.times.4 group of load bearing elements). The bridging connection
between elements prevents neighboring support elements from
pinching the body between them as they flex differentially.
[0011] In a similar implementation, the pixelated support structure
may include a support spine, a first spline laterally disposed
across the support spine, and multiple pixelated support elements
connected to the spline in a longitudinal array across the spline.
A wide variety of pixelated support elements may be employed. As
one example, one or more of the pixelated support elements may
include a spline connection, a spring arm emerging from the spline
connection, and a load bearing element at the end of the spring
arm.
[0012] Generally, the support spine may be curved in accordance
with a selected anatomical structure. Thus, as examples, the
support spine may take the form of a back rest curved spine, or a
seat rest curved spine.
[0013] In addition, the support spine may be flexible lengthwise so
that the support elements follow gross motions of the body. The
overall support structure may then have a springing action all
along its length (both cantilever and torsional), or may be hinged
along its length and driven into the desired position, for example,
by rigid body mechanics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates an elastic block pixelated support
element resting a spring cradle.
[0015] FIG. 2 depicts a spring arm pixelated support element
resting in a spring cradle.
[0016] FIG. 3 illustrates an interconnection structure for
pixelated support elements.
[0017] FIG. 4 shows another example of a pixelated support
element.
[0018] FIG. 5 illustrates a perspective view of a pixelated support
element including an upper support layer, a lower base layer, and a
tensile membrane between the upper support layer and the lower base
layer.
[0019] FIG. 6 shows a side view of the pixelated support element of
FIG. 5.
[0020] FIG. 7 shows a pixelated support element including a double
action spring.
[0021] FIG. 8 portrays a pixelated support element including two
support arms.
[0022] FIG. 9 shows a second view of the pixelated support element
of FIG. 7.
[0023] FIG. 10 illustrates exemplary dimensioning for the pixelated
support element shown in FIG. 7.
[0024] FIG. 11 depicts a support structure including pixelated
support elements lending a rotational aspect to the load bearing
elements.
[0025] FIG. 12 shows another example of a support structure
including multiple pixelated support elements.
[0026] FIG. 13 shows a pixelated support element of FIG. 12, in an
uncompressed and a compressed state.
[0027] FIG. 14 shows a pixelated support structure including load
bearing elements support by cantilevers.
[0028] FIG. 15 depicts a second view of the pixelated support
structure of FIG. 14.
[0029] FIG. 16 shows a pixelated support structure including a
flexible spine and crossing splines.
[0030] FIG. 17 shows another view of the pixelated support
structure of FIG. 16.
[0031] FIG. 18 shows a side view of the pixelated support structure
shown in FIG. 11.
[0032] FIG. 19 shows a side view of the pixelated support structure
shown in FIG. 12.
[0033] FIG. 20 shows an interconnected set of pixelated support
elements.
[0034] FIG. 21 presents a support diagram of the human body.
[0035] FIG. 22 shows a cutaway section of a continuous surface that
includes individual support elements.
[0036] FIG. 23 illustrates a variation of the support element
illustrated in FIG. 8.
[0037] FIG. 24 portrays a variation on the cantilevered support
structure shown in FIG. 14.
[0038] FIG. 25 presents a second view of the cantilevered support
structures shown in FIG. 24.
[0039] FIG. 26 shows a section of support elements arranged along a
common spine.
[0040] FIG. 27 illustrates a variation of the pixelated support
element shown in FIG. 7.
[0041] FIG. 28 portrays a support element made from a wire and
mesh.
[0042] FIG. 29 shows a support element made form a wire and
mesh.
[0043] FIG. 30 illustrates an extruded section of support elements
such as those shown in FIG. 8.
[0044] FIG. 31 shows a view of a multi-tier pixelated support
structure.
[0045] FIG. 32 shows a second view of the multi-tier pixelated
support structure shown in FIG. 31.
[0046] FIG. 33 illustrates a third view of the multi-tier pixelated
support structure shown in FIG. 31.
[0047] FIG. 34 shows dimensional information for the multi-tier
pixelated support structure shown in FIG. 31.
[0048] FIG. 35 shows a view of another implementation of a
multi-tier pixelated support structure.
[0049] FIG. 36 shows a second view of the multi-tier pixelated
support structure shown in FIG. 35.
[0050] FIG. 37 illustrates a third view of the multi-tier pixelated
support structure shown in FIG. 35.
[0051] FIG. 38 shows dimensional information for the multi-tier
pixelated support structure shown in FIG. 35.
[0052] FIG. 39 shows a side view of a multi-tier pixelated support
structure.
[0053] FIG. 40 shows a top view of a multi-tier pixelated support
structure.
[0054] FIG. 41 shows a perspective view of a multi-tier pixelated
support structure.
[0055] FIG. 42 shows a side view of a multi-tier pixelated support
structure.
[0056] FIG. 43 shows a perspective view of a multi-tier pixelated
support structure.
[0057] FIG. 44 shows a top view of a torsional pixelated support
structure.
[0058] FIG. 45 shows a bottom view of a torsional pixelated support
structure.
[0059] FIG. 46 shows a side view of a multi-bar pixelated support
structure.
[0060] FIG. 47 shows a perspective view of a multi-bar pixelated
support structure.
[0061] FIG. 48 shows a top view of a multi-bar pixelated support
structure.
[0062] FIG. 49 shows a pixelated support structure running on an
underlying supporting structure.
[0063] FIG. 50 shows a pixelated support structure with translating
load bearing elements.
[0064] FIG. 51 shows a pixelated support structure with translating
load bearing elements.
[0065] FIG. 52 shows a multiple tier pixelated support
structure.
[0066] FIG. 53 shows a structural rocker and arm that may be
incorporated into a pixelated support structure.
[0067] FIG. 54 shows a bottom view of a torsional pixelated support
structure.
[0068] FIG. 55 shows a bottom perspective view of a torsional
pixelated support structure.
[0069] FIG. 56 shows an enlarged view of a portion of a torsional
pixelated support structure.
[0070] FIG. 57 shows a side view of a torsional pixelated support
structure.
[0071] FIG. 58 shows a side view of a torsional pixelated support
structure.
[0072] FIG. 59 shows a triangular load bearing element.
[0073] FIG. 60 shows a bottom view of a pixelated support
structure.
[0074] FIG. 61 shows an isometric view of a pixelated support
structure.
DETAILED DESCRIPTION
[0075] Before turning to a detailed discussion of the Figures, it
is noted that pixelated body support generally refers to an array
of individual body-support elements that in combination provide
support for some or all of an individual's body. For example, the
body support may include an array of closely spaced pixelated
support elements that define a support surface for an individual.
As will be explained in more detail below, the pixelated support
elements may take many forms, including, for example a
spring-loaded element formed as, or biased by, mechanical or
pneumatic springs or by other devices. Furthermore, the stiffness
or biasing force of the pixelated support elements may be
individually designed as desired to suit the particular body
support needs of the individual and the application.
[0076] Several exemplary implementations of pixelated support
elements (referred to below as "elements" or "support elements")
are discussed next. Subsequently, pixelated support structures that
may incorporate the pixelated support elements are presented.
[0077] With regard first to FIG. 1, that figure shows two pixelated
support elements 100, 102. The support element 100 is shown in an
uncompressed state, while the support element 102 is shown in a
compressed state. Each support element 100, 102 may be constructed
in the same manner. For example, the support element 100 includes a
spring cradle 104 that may generally be regarded as including a
cradle base 106 and a spring support structure 108. In addition, a
spring element 110 is partially disposed in the spring cradle 104.
As shown in FIG. 1, the spring cradle 104 provides an open area
forming a spring compression area 112. The spring cradle 104 is
attached (e.g., through adhesive bonding or mechanical linkage) to
a spline 114.
[0078] In this instance, the spring element 110 is an elastic
element that is shown as roughly rectangular or block shaped.
However, it is noted that any other geometric shape may be used
instead, depending on the desired characteristics of the particular
design. Because the spring element 110 is elastic, it therefore
deforms as weight is applied (e.g., as element 102 illustrates),
and recovers as the weight is removed (e.g., as element 100
illustrates). In one implementation, the spring element 110 may be
a gel filled structure.
[0079] The spring compression area 112 is shown as an open space
between the spring element 110 and the spring support structure
108. The larger the spring compression area 112, the softer the
associated spring element 110 feels. Likewise, the smaller the
spring compression area 112, the stiffer the associated spring
element 110 feels. Thus, as examples, the radius and depth of the
spring cradle 104 may be individually designed for each spring
cradle to provide a pre-selected amount of stiffness for the
associated spring element 110.
[0080] FIG. 2 shows a top view and a side view of a second
pixelated support element 200. The element 200 includes a spring
cradle 202 that may generally be regarded as including a cradle
base 204 and a spring support structure 206. The cradle base 204
attaches to the spline 208. In addition, a spring element 210 is
partially disposed in the spring cradle 202. The spring element 210
includes four elastic spring arms 212, 214, 216, 218, although
additional or fewer support arms may be used in other
implementations.
[0081] At end of each spring arm 212-218 is an L-shaped load
bearing element 220, 222, 224, 226. Other shapes are also suitable.
Thus, as examples, the load bearing elements 220-226 may be square,
rectangular, or circular.
[0082] The spring support structure 206 is formed as a cradle arm
for each elastic spring arm 212-218. The cradle arm extends along
the elastic spring arms 212-218, thereby imparting a pre-selected
tension in the each spring arm 212-218. The tension may be
individually adjusted for each spring arm 212-218, and individually
adjusted from support element to support element by changing the
materials, dimensions, or length of cradle arm extending along the
elastic spring arm. The height of the cradle arm is denoted in FIG.
2 as dimension A.
[0083] FIG. 3 illustrates an interconnection structure for
pixelated support elements. In particular, FIG. 3 shows a first
support element 302 and a second support element 304. Each support
element 302-304 may be constructed as noted above with regard to
FIG. 2, as an example. However, rather than or in addition to being
attached to a spline, the support elements 302-304 may include
their own branches 306.
[0084] Each branch 306 includes an interconnection mechanism at
each end. The interconnection mechanism may include a male
connector 308 on one end of the branch 306 and a mating female
connector 310 on the opposite end of the branch 306. Then support
elements 302-304 may then be coupled together to form a linear
array of elements in which the connected branches 306 form a
spline.
[0085] FIG. 4 shows another example of pixelated support elements
400 arranged along a spline 402. The elements 400 are formed as a
curved shell 404 that terminates in a spring arm 406. The spring
arm 406 may be formed as an undulating section of material that
provides tension and a restorative force when a load is applied
that causes a portion of the curved shell 404 pushes down on the
spring arm 406.
[0086] Turning next to FIG. 5, that figure shows a perspective view
of a pixelated support element 500. More specifically, the
pixelated support element 500 includes an upper support layer 502
and a lower base layer 504. An elastomer material 506 is disposed
between the upper support layer 502 and the lower base layer
504.
[0087] FIG. 6 shows a side view of the pixelated support element
500 of FIG. 5. FIG. 6 shows that the upper support layer 502
includes a series of peaks 602 and valleys 604. Similarly, the
lower base layer 504 includes a series of peaks 606 and valleys 608
disposed such that the peaks 606 align with the valleys 604.
[0088] The peaks 602 and 606 are characterized by a separation
distance that may vary from peak to peak. FIG. 6 illustrates three
such separation distances in decreasing order of magnitude with
reference numerals 610, 612, and 614. Similarly, FIG. 6 shows that
the peaks and valleys may have independently adjustable heights and
depths, as shown by reference numerals 616 and 618. The depths and
heights provide a pre-selected travel distance for the upper
support layer 502. As one example, the travel distance may be set
to be approximately 1 inch, although longer and shorter distances
may also be employed.
[0089] The elastomer material 506 stretches both up and down when a
load is applied to the upper support layer 502. The spring range
provided by the elastomer material 506 is determined by the height
of the peaks of both the upper support layer 502 and the lower base
layer 504. In one implementation, the height of the peaks and the
depths of the valleys may be approximately 1 inch. The spring rate
may be varied by changing the separation distance between peaks as
shown in FIG. 6.
[0090] For example, when the separation distance is greater (as
shown on by the separation distance 610 on the left side of FIG.
6), the corresponding portion of the element 500 provides a softer
feel. Alternatively, when the separation distance is less (as shown
by the separation distances 612-614 on the right side of FIG. 6),
then the element 500 also provides a stiffer feel. As examples, the
separation distances 610, 612, and 614 may be 2.0 inches, 1.625
inches, and 1.5 inches. In addition, the material or thickness of
the elastomer material 506 may be varied at design time to impart
addition or lesser stiffness in any particular area. The elastomer
material 506 may be made from many different materials, including a
polymer material such as Hytrel.TM. material (elasticized
polyethelene), Santoprene.TM. material (elastomerized
polypropylene), Polyisopene.TM. material, or a polybutadience or
polyurethane material.
[0091] Thus, the element 500 allows the spring rate and resultant
stiffness to be tailored across the element 500. As a result, the
element 500 may be made stiffer where significant pressure is
exerted, and softer where less pressure is exerted (or when a
softer feel is desired).
[0092] FIG. 7 provides another example of a pixelated support
element 700. The element 700 includes an upper load bearing element
702, a lower base element 704, and a spring system between the
upper load bearing element 702 and the lower base element 704. The
spring system includes a compression spring 706 between the upper
and lower elements 702-704, and an elastomeric spring 708 disposed
below the compression spring 706. The two springs 706-708 provide
sufficient restoring force, while allowing a height reduction in
which the element 700 functions.
[0093] The compression spring 706 may be a conical compression
spring integrally molded to the upper load bearing element 702. The
elastomeric spring 708 may then be an elastomeric membrane retained
co-axially with the compression spring 706. Retention may be
accomplished using the perimeter of the compression spring 706, or
by adding a nipple to elastomeric spring 708 to retain the
compression spring 706.
[0094] In one implementation, the compression spring 706 is
substantially softer than the elastomeric spring 708 and thus
compresses first. When compressed, the compression spring 706 may
then form a conical solid plunger that engages the elastomeric
spring 708. The elastomeric spring 708 then begins to stretch in
elongation.
[0095] The overall element 700 may provide linear spring action in
two regions: first during compression of the compression spring 706
(and minor stretching of elastomeric spring 708) and then a second,
steeper spring rate as the elastomeric spring 708 stretches. Either
spring 706-708 may be set to be the primary travel, or it may be
evenly split between the two springs 706-708.
[0096] FIG. 7 shows that the upper load bearing element 702 may be
formed into a pixelated upper load bearing element array. For
example, the upper array may include the pixelated elements 710,
712, 714, 716 in a 2.times.2 array. The lower base element 704 may
then be formed as a pixelated lower base element array, including
corresponding pixelated elements 718, 720, 722, 724. The pixelated
elements 710-724 may individually biased by spring systems and may
be interconnected with hinges, such as a living hinge, or with
another shape such as the peak and valley shape shown in FIG. 7.
Although FIG. 7 shows 2.times.2 pixelated arrays of square
pixelated elements 710-724, the array may be larger or smaller in
any particular dimension, and may include pixelated elements that
are rectangular, round, or any other shape.
[0097] FIGS. 8-10 show another implementation for a pixelated
support element 800. FIGS. 8 and 9 provide a perspective view of
the element 800, which includes a spline connection 802, spring
arms 804 and 806, and load bearing elements 808 and 810. The
element 800 may be a single molded piece (e.g., of thermoplastic
elastomer), or constructed from separate components secured
together by fasteners. In one implementation, the load bearing
elements 808 and 810 of the support element 800 retain horizontal
orientation when loaded with a vertically downward force.
[0098] The spline connection 802 provides an interference fit
connector that may slide onto or snap onto a generally round
spline. More generally, the spline connection 802 provides a base
connection that may be attached or adhered to an underlying support
structure. In an alternate embodiment, however, the support element
800 may be molded as a single piece with a spline or with a spline
and a spine, such as those shown below in FIGS. 16 and 17. As
another example, the base connection 802 may include cross pin
holes through which a securing pin may be inserted to secure the
support element 800 to a spline (including matching cross pin
holes).
[0099] The underlying support structure may be a substantially one
dimensional spline, or may be a two dimensional rigid or flexible
backing structure. The backing structure may take the shape, as
examples, of a backrest or a seat rest for a chair, optionally
ergonomically curved. Thus, the backrest may be curved to provide
back support that includes lumbar support, while the seat may be
curved to provide support that matches the natural curves of the
buttocks and thighs.
[0100] The spring arms 804 and 806 emerge from the spline
connection 802 to provide a pair of compression arms that extend
upwardly from the spline connection 802. The load bearing elements
808 and 810 are then connected to the free ends of the spring arms
806 and 804 respectively. As shown in FIGS. 8-10, the spring arms
804, 806 are formed in an undulating or zig-zag shape to provide a
biasing force.
[0101] FIG. 10 provides exemplary dimensions for the element 800
that are particularly suitable when the element 800 is incorporated
into a pixelated support structure in a chair.
[0102] FIG. 11 depicts a support structure 1100 including pixelated
support elements (three of which are labeled 1102, 1104 and 1106)
coupled together. More specifically, each of the pixelated support
elements, for example the element 1102, includes a load bearing
element 1108, and rotational arms 1110, 1112, and 1114. Rotational
arms from sets of three neighboring pixelated support elements
connect along a helix shaped path at a lower support coupling
present at the end of each rotational arm. One lower support
coupling is labeled 1116 at the end of the rotational arm 1112.
[0103] Although the load bearing elements are show as circular,
they may take another shape in accordance with the particular
design. The helical rotational arms 1110-1114, through the support
couplings, allow the pixelated support elements to rotate
off-center (e.g., as shown, counterclockwise) and move together
when a load is applied to the load bearing elements. The load
bearing elements may thus provide a shearing action that provides a
pleasant feel to the body.
[0104] In general, the support structure 1100 may be formed through
a molding process. In particular, a thermoplastic elastomer may be
injected into a mold providing the load bearing element, rotational
arm, and support coupling elements set forth above.
[0105] Turning briefly to FIG. 18, that Figure shows a side view
1800 of a portion of the support structure 1100. FIG. 18 shows the
load bearing element 1108 and its three helical rotational arms
1110, 1112, and 1114. The helical rotational arm 1112 is shown
connected to the support coupling 1116. The support couplings may
be secured to a rigid base of an underlying support structure.
[0106] FIG. 12 shows another example of a support structure 1200
including multiple pixelated support elements 1202. Each support
element 1202 includes four load bearing elements, for example, the
load bearing elements 1204, 1206, 1208, and 1210. A lower base
element 1212 is provided for each support element 1202, and
cantilever support arms 1214, 1216, 1218, and 1220 connect the load
bearing elements 1204-1210 to the lower base element 1212. A
distance R separates the lower base element 1212 and the load
bearing elements. Material cutouts 1222 and 1224 are also
shown.
[0107] The support structure 1200 may be formed in a manner similar
to the support structure 1100. For example, a mold may be formed to
provide the load bearing element, base element, and support arm
shapes shown in FIG. 12. A thermoplastic elastomer may then be
injected into the mold to realize the support structure 1200. The
base elements may be secured to a rigid base of an underlying
support structure.
[0108] FIG. 13 shows a side view 1300 of a portion of the support
structure 1200, in an uncompressed state 1302 and a compressed
state 1304. As shown in FIG. 13, the cantilever support arms 1218
and 1220 couple load bearing elements 1204 and 1210 to a lower base
element 1212. The cantilever support arms 1218 and 1220 will
deflect in an arc when a load is applied to the load bearing
elements 1204 and 1210. The spacing of the bearing elements
equalizes as the elements are deflected downwards. The materials,
dimensions, and construction of the cantilever support arms 1218
and 1220 may be independently designed and selected to impart a
desired stiffness, and may, for example, provide approximately 1
inch of vertical travel and (1/2)*R horizontal travel under
compression.
[0109] Turning briefly to FIG. 19, that Figure shows a side view
1900 of a portion of the support structure 1200. The side view
shows the state of the support structure 1200 in an unloaded state.
More specifically, FIG. 19 shows the load bearing elements 1204 and
1210 connected by the cantilever support arms 1218 and 1220 to the
base element 1212.
[0110] The pixelated support elements discussed above (or those of
other design) may be incorporated into pixelated support
structures, several examples of which are set forth below.
[0111] With regard next to FIG. 14, a pixelated support structure
1400 is shown. The structure 1400 includes splines 1402, 1434, and
1436, cantilever branches (four of which are labeled 1404, 1406,
1408, and 1410) that extend outwardly from the spline 1402, and
load bearing elements (six of which are labeled 1412, 1414, 1416,
1418, 1420, and 1422).
[0112] FIG. 14 also shows two support spines 1424 and 1426. The
spline 1402 is disposed laterally across the support splines 1424
and 1426 as shown. The cantilever branches 1404-1410 generally may
be regarded as including a terminal end connected to the spline
1402 (or integrated with the spline 1402, for example as a single
injection molded piece) and a support end opposite the terminal
end. One terminal end is labeled 1428 and one support end is
labeled 1430 in FIG. 14.
[0113] The load bearing element 1412 connects to the support end of
the cantilever branch 1406, and the load bearing element 1414
connects to the support end of the cantilever branch 1404.
Similarly, the load bearing element 1416 connects to the support
end of the cantilever branch 1408, while the load bearing element
1418 connects to the support end of the cantilever branch 1410.
[0114] Bridging connections may connect the individual load bearing
elements. The bridging connections give surface continuity that
prevents pinching of the skin. For example, as shown in FIG. 14,
the bridging connection 1432 connects the load bearing elements
1412, 1414, 1416, and 1418 at their corners. The bridging
connection 1432 forms a junction for the four load bearing elements
1412-1418. In other words, sequences of four load bearing elements
are connected together (e.g., at their corners) to form 2.times.2
pixelated groups that extend in a linear array laterally across the
spline 1402. In other implementations, the groups may be larger
than a 2.times.2 group or smaller than a 2.times.2 group. The load
bearing elements 1412-1418 are otherwise disconnected from one
another, and thereby provide an independent pixel support for the
body part at rest on the particular load bearing element.
[0115] The spines 1424 and 1426 may support additional splines
disposed from one another and constructed as noted above, including
as examples the splines 1434 and 1436. Thus, the load bearing
elements not only extend laterally across the splines, but also
longitudinally along the spines 1424 and 1426. When bridging
connections are added to couple together sets of four load bearing
elements, a two dimensional pixelated mat of load bearing elements
is formed and supported by the spines 1424-1426. Each of the
cantilever branches may be independently designed by selection,
dimension, and composition of materials and dimensioning to provide
a pre-selected stiffness, adjusted, for example, according to the
body part supported by the load bearing element attached to the
cantilever branch.
[0116] The spines 1424-1426 may be curved to accommodate a selected
anatomical structure. For example, in FIG. 14, the spines 1424-1426
are curved to form an ergonomic seat rest. As another example, the
spines 1424-1426 may also be curved to form a back rest, including
lumbar support.
[0117] FIG. 15 depicts an alternate implementation of a pixelated
support structure 1500 similar to that shown in FIG. 14. In FIG.
15, a spine 1502 supports five splines 1504, 1506, 1508, 1510, and
1512 disposed laterally across the spine 1502. Each spline includes
one or more cantilever branches to either side of the spine 1502.
Several of the cantilever branches for the spline 1504 are labeled
1514, 1516, 1518, and 1520.
[0118] Although not illustrated in FIG. 15, one or more of the
cantilever branches may support a load bearing element as
illustrated above in FIG. 14. Additionally, the load bearing
elements may be connected via bridging connections to form pixel
groups of multiple bearing elements. As shown above in FIG. 14, the
bridged load bearing elements may then form a one dimensional array
laterally across a given cantilever branch, or a two dimensional
array extending across multiple cantilever branches.
[0119] Turning next to FIG. 16, a pixelated support structure 1600
includes a spine 1602 and one or more perpendicularly crossing
splines (two adjacent splines are labeled 1604 and 1606). Each
spline 1604, 1606 will carry one or more pixelated support elements
to form a one dimensional array of support elements laterally
across a given spline. When multiple adjacent splines carry the
pixelated support elements, the elements may then form a two
dimensional array extending along the spine 1604 in one dimension
and along the splines 1604-1606 in a second dimension.
[0120] As shown in FIG. 16, the spine 1602 is curved to form a back
rest, including lumbar support. Note also that a similar spine 1608
and crossing splines (e.g., the spline 1610) may also be provided
to form an ergonomically curved seat rest. The splines 1604, 1606,
and 1610, in one implementation, may have a substantially round
cross section. The splines 1604, 1606, 1610 may also be curved
(e.g., initially away from the spines 1602, 1608) to form a
curvature, depression or other shape for supporting the back or
buttocks. Suitable construction materials include glass filled
nylon, polycarbonates, Polyethylene Terephthalate (PET) plastics,
and the like.
[0121] One or more sections of the spines may be implemented using
a flexible material. Thus, for example, the spine 1602 may include
an upper spine section 1612 and a lower spine section 1614 that may
flex either by chair kinematics or user movement. The upper spine
section 1612 and the lower spine section 1614 may be joined at an
inflection point 1616 that may be a floating inflection point, for
example. The inflection point may be implemented using a pin,
hinge, or other coupling structure. In this manner, for example,
the support structure 1600 may act as an analog of the human spine,
in that the spine section 1612 will flex together with the human
spine (e.g., as the user reclines).
[0122] In one implementation, the upper spine section 1612 flexes
backwards while the lower spine section 1614 flexes forward. To
this end, the upper spine section 1612 may, for example, be sprung
forward with a cable and spring assembly that can be overcome by
pushing back against the upper spine section 1612. Thus, instead of
the support spine 1602 being a relatively rigid structure, the
support spine 1602 may instead flex along one or more sections. As
shown in FIG. 16, for example, the lower spine section 1614 flexes
inward to support the lower back, and the upper spine section 1612
flexes backwards. The spine 1602, splines, and support elements may
be formed individually or in combination as a single molded
piece.
[0123] FIG. 17 shows another view of a pixelated support structure
1700 similar to that shown in FIG. 16, but including pixelated
support elements. In FIG. 17, splines laterally cross supporting
spines (occluded in this view). As with the implementation shown in
FIG. 16, the spines may be constructed as one or more sections of
flexible spine sections to provide, for example, a flexible support
for the upper and lower back. For example, the spline 1702 extends
across a back rest spine near the top of the back rest spine. The
spline 1702 carries multiple pixel support elements 1704. Five of
the support elements 1704 are shown in position across the
innermost portion of the spline 1702, including a first support
element 1706 and a fifth element 1708.
[0124] The pixel support elements 1704 may be selected from any of
the pixel support elements described above. For example, the pixel
support elements shown in FIGS. 8, 9, and 10 may be connected to
(or integrally molded with) the splines through their spline
connection 802.
[0125] Note that each support element 1704 may then include spring
arms 804 and 806, and load bearing elements 808 and 810 at the end
of the spring arms 804 and 806. As noted above, each support spring
arm 804 and 806 may then be independently designed to provide a
pre-selected stiffness. In that manner, each support element 1704
may provide a different level of resistance and support to provide
an enhanced ergonomic and comfortable body support.
[0126] Many different spring designs may be employed to form a
pixelated support element. One example is shown in FIG. 20, which
shows an interconnected spring system 2000 that includes multiple
interlinked springs 2002, 2004, 2006, and 2008. The spring system
2000 includes an initial termination 2010, which winds into a first
spring coil 2012 (as shown, including two turns). The first spring
coil 2012 continues through a relatively straight connector 2014
through a neighboring spring interlinking point 2016 and into a
second spring 2018 (as shown, also including two turns). The spring
system 2000 continues across the springs 2004, 2006, and 2008 until
it reaches the final termination 2020.
[0127] The spring system 2000 may be implemented, for example,
using Dux.RTM. D-springs available from Dux company of Sweden as
part of the Dux Pascal.TM. spring system. The Pascal.TM. spring
system is a cassette system, in which each cassette includes a
continuous wire spring inside of tube pockets with a fabric mesh
outer layer or shell. The cassettes may be ordered by specifying
wire diameter and size. The size may include the number of springs
along in one dimension and the number of rows of springs along a
second dimension.
[0128] Cassettes of different specifications may be employed as
desired across a pixelated support structure to tailor support for
any part of the body. Thus, for example, stiffer cassettes may be
employed where additional support is desired, while softer
cassettes may be employed where less support is needed.
[0129] As one example, the pixelated support elements may be
designed to give approximately 5 pounds of force at a one inch
deflection (per support element). That amount of force may be
independently chosen according to the individuals who will use the
support structures. For example, taking a hypothetical male
weighing 250 lbs, that individual has a median distribution
approximated by 5 lbs/4 sq. inches (the area of a 2.times.2 inch
pixel) in the neutral seated position. The values may increase to 9
lbs/4 sq. inches in some areas, and drop to zero around the
periphery of the pixel.
[0130] Table 1, below, depicts an array of 2''.times.2'' support
elements supporting the hypothetical individual noted above and
were obtained through pressure mapping. The value in each cell is
the load carried by that area, with the front of the seat
horizontally at the bottom of the table (left to right), and with
the centerline of the seat vertically along the table (bottom to
top).
TABLE-US-00001 TABLE 1 0.0475 0.8075 1.33 1.2425 0.955 3.68 4.195
5.46 2.98 6.595 8.0925 6.1325 5.4025 6.15 8.7675 7.4525 5.025
6.1375 6.6375 3.42 3.745 4.54 4.705 2.4175 2.2825 4.37 4.94 2.105
0.1425 1.2425 1.2125 0.0675
[0131] The pressure map shown in Table 1 may thus help indicate the
particular support element stiffnesses desired at any given point,
or for any given part of the body.
[0132] Exemplary relative pixel size, material, and stiffness
include: Small: Hytrel 4074.TM. material, Flex Mod 9.5 ksi, 2.8
lb/in, Medium: Hytrel 4774.TM. material, Flex Mod 17 ksi, 5 lb/in,
Large: Hytrel 5526.TM. material, Flex Mod 30 ksi, 8.8 lb/in,
extra-large: Hytrel 6356.TM. material, Flex Mod 48 ksi, 14.1 lb/in,
and extra-extra-large: Hytrel 7246.TM. material, Flex Mod 83 ksi,
24.4 lb/in.
[0133] FIG. 21 shows a support diagram 2100 of the human body that
indicates exemplary locations where additional support may be
provided by pixelated support elements. For example, the support
elements may be tailored to provide additional support for the
cranial cap 2102 or along all or some of the cervical spine 2104.
Similarly, the latissimus dorsi muscles 2106, lumbar/sacrum area
2108 and ischia (the sit bones) 2110 may be targeted for additional
support. Other areas that may receive support include the hind leg
2112, feet 2114, and arms 2116 between the wrist and elbow.
[0134] The spring rate of the support elements may be individually
set for any of the locations. Thus, firmer support may start at
higher load areas, with the support optionally feathering out as
the support surface extends away. For example, firm support may be
provided along the spine 2104, and softened laterally away form the
spine 2104.
[0135] Addition examples of pixelated support elements and their
implementations are discussed below. For example, with regard to
FIG. 22, a support element 2200 is shown in a bottom view 2202 and
a top view 2204. The support element 2200 represents a cutaway
section of a continuous surface. The support element 2200 includes
a porous or textured layer 2206 formed, as examples from foam or a
soft composite material. The textured layer 2206 provides the
primary interface between the sitter and the suspension elements
2208.
[0136] The suspension elements 2208 may be implemented as springs
that rest in a cup 2210. The springs may be steel springs, thereby
providing a wide range of spring rate tuning capability. The cups
2210 provide an intermediate transition between the soft textured
layer 2206 and the springs and a relatively rigid bottom structural
surface 2212. Note that the textured surface 2206 may be relieved
to enhance air flow and reduce heat buildup.
[0137] FIG. 23 presents a support element 2300 that is a variation
on the pixelated support element 800 shown in FIG. 8. Specifically,
the support element 2300 includes cutouts 2302, 2304, 2306, and
2308 in the load bearing elements 808 and 810. The cutouts
2302-2308 may optionally be included to provide a porous surface
that enhances aeration through the textile material interface
support on the load bearing elements 808 and 810.
[0138] FIGS. 24 and 25 present pixelated support structures 2400
and 2500 that are a variation on the pixelated support structures
1400 shown in FIG. 14. In particular, rather than connecting the
load bearing elements with bridging connections, the load bearing
elements are independent. As examples, the seat rest support
elements 2402, 2404, and 2406 are not connected by bridging
connections. Similarly, the back rest support elements 2502, 2504,
and 2506 project up from their support spline without
interconnection between other support elements.
[0139] The interface between the sitter and the support elements
(e.g., a soft foam or fabric support) may be made thicker to mask
the independent support elements. As noted above, each cantilever
branch may be individually tuned to provide selected stiffness. As
a result, the seat rest or back rest may provide stiffer or softer
support for the body at selected locations.
[0140] Turning next to FIG. 26, that figure presents a section 2600
of support elements 2602 arranged along a central spine 2604. Each
support element 2602 includes two cantilever sections 2606 and
2608. Each cantilever section 2606 includes a load bearing element
2610 and two spring arms 2612 and 2614.
[0141] The spring arms 2612 and 2614 form a spring that collapses
upon itself. The support elements 2602 may, for example, be
attached to the spines that form the back rest or seat rest shown
in FIG. 14-17, 24, or 25 instead of the cantilevered support
elements. The support elements 2602 may be manufactured from
Hytrel.TM. material in an injection molding process. In one
implementation, there is approximately 2.0 inches between load
bearing element centers, and approximately 1.5-2.0 inches
vertically from the spine 2604 to the load bearing elements
2610.
[0142] FIG. 27 shows a support element 2700 that is a variation of
the double action spring pixelated support element 700. More
specifically, the support element 2700 includes an upper load
bearing element 2702, a lower base element 2704, and a spring
system 2706 between the upper load bearing element 2702 and the
lower base element 2704.
[0143] The spring system 2706 includes the cantilever elements 2708
made of a flexible material. The cantilever elements 2708 flex
downwardly to resist the action of the plunger elements 2710 that
extend downward from the upper load bearing element 2702. In
particular, the cantilever elements 2708, arranged conically,
invert to constantly resist the plunging action of the plunger
elements 2710.
[0144] The lower base element 2704 and cantilever elements 2708 may
be formed from an elastomer, such as Hytrel.TM. material, while the
upper support element 2702 may be, for example, polypropylene. A
co-molding process may be employed to form the lower base element
2704 to integrate the cantilever elements 2708 into the more rigid
lower base element 2704.
[0145] In addition, the V-slots 2712 may be included to provide a
living hinge between individual lower base elements. Optionally,
the intersection of each set of four support elements is left open.
As a result, the plunger elements 2710 may articulate to some
degree.
[0146] Turning to FIG. 28, that figure shows a support element 2800
fabricated from parallel wires 2802 (e.g., steel wire) and mesh
2804 attached between the wires 2802. The support element 2800 may,
as shown, be formed into an undulating shape that provides spring
action for compression and restoration. The mesh 2804 may be a
three dimensional knitted material In one implementation, the mesh
2804 is a `3 mesh` manufactured by Muller Textil of Woonsocket,
R.I., USA. The mesh 2804 may provide the interface between the
sitter and the support element 2800 as a whole.
[0147] FIG. 29 also shows a support element 2900 fabricated from
mesh 2902 and spring action filaments 2904. The support element
2900 is formed in a tapered cylindrical shape, though other shapes
may also be employed. The top of the truncated tapered cylinder
forms a load bearing element. The mesh 2902 may be implemented in
the same way as noted above with regard to the support element 2800
shown in FIG. 28.
[0148] The filaments 2904 may be nylon filaments woven by hand into
the wall of the mesh 2902. The filaments impart a spring effect to
the mesh 2902 and thereby provide a restorative force as the mesh
2902 deforms when a load is applied to the load bearing element. In
general, either of the support elements 2800 or 2900 may, be
characterized by a distance of approximately 2.0 inches between
load bearing element centers, and approximately 1.5-2.0 inches of
vertical travel.
[0149] FIG. 30 shows a section 3000 of support elements 3002
connected at bridging connections 3004 (e.g., a hinge) between load
bearing elements 3006. The load bearing elements 3006 are present
at the end of spring arms 3008. The support elements 3002 may be,
for example, the support elements illustrated above in FIG. 8 or
23.
[0150] When the support elements 3002 are connected as shown in
FIG. 30, the section 3000 imparts a degree of control over the load
bearing elements 3006. In other words, the bridging connections
3004 may constrain movement of the load bearing elements 3006 so
that they do not catch or pinch the sitter.
[0151] The section 3000 may be extruded as a single piece.
Individual sections may then be cut apart in desired lengths to be
attached, as examples, to the back rest or seat rest spines shown
in FIGS. 14-17 and 24-25. The sections may be attached by employing
a mechanical means of snapping or dovetailing the sections 3000
onto the spines. When the wall thickness of the spring arms 3008 is
held approximately constant, extruding multiple support elements
3002 in a section 3000 may yield a consistent spring rate among
multiple support elements 3002. On the other hand, when the wall
thickness of the spring arms 3008 is varied, the spring rate may be
changed. For example, the spring arms 3008 for the central support
elements 3002 may be made thicker to increase the spring rate for
those support elements 3002, and thereby provide additional
support.
[0152] FIG. 31 shows a view of a multi-tier pixelated support
structure 3100. The structure 3100 includes a first tier 3102, a
second tier 3104 and a third tier 3106. The third tier 3106
supports load bearing elements 3108 that may vary in shape and
size. Although sixteen (16) load bearing elements 3108 are shown in
FIG. 31, the structure 3100 may include more or fewer load bearing
elements. The structure 3100 may couple tiers 3102-3106 together
through hinges such as hinges 3110, 3112, and 3114 as examples.
[0153] Each hinge may be formed from cantilevers or living hinges.
For example, the hinge 3112 includes a first H-shaped cantilever
3116 and a second perpendicularly oriented H-shaped cantilever
3118. Accordingly, the tiers and load bearing elements may support
loads by bending in two independent directions.
[0154] The hinges may be manufactured from polypropylene, for
example. The structure 3100 may be formed in individual pieces for
the load bearing elements, hinges, and tiers. The pieces may then
be snapped or otherwise secured together to form the overall
structure 3100.
[0155] The first tier 3102 may provide a connection mechanism to an
underlying support structure to which the structure 3100 will
attach. The connection mechanism may be a snap-on interface, bolt
or screw holes, or any other type of connection mechanism. Multiple
structures 3100 may be attached to the underlying support structure
to form a larger pixelated support surface for the back, seat,
arms, or other area of the body.
[0156] The size of the load bearing elements 3108, the size of the
cantilevers, and the materials that form the structure 3100 may be
independently adjusted to tailor the support provided by the load
bearing elements. For example, a back rest incorporating the
structure 3100 may adjust the size of the load bearing elements
3108 to increase support closer toward the spine and down the
back.
[0157] FIGS. 32 and 33 show additional views of the multi-tier
pixelated support structure shown in FIG. 31. FIG. 32 shows the
structure 3100 from the bottom. FIG. 33 illustrates a side view of
the structure 3100. The second tier 3106 may include four
sub-tiers, three of which are visible in FIG. 32 as sub-tiers 3202,
3204, and 3206. Each sub-tier may connect to the first tier 3102
through H-shaped cantilevers oriented at 90 degrees to one
another.
[0158] FIG. 34 shows exemplary dimensional information for the
multi-tier pixelated support structure 3100. The structure 3100 may
vary widely in size and shape to suit any particular design. Thus,
any of the load bearing elements 3108, tiers 3102-3108, and
H-shaped cantilevers may be independently sized and shaped. In the
example shown in FIG. 34, the structure 3100 includes sixteen (16)
load bearing elements that vary in length and width. The structure
is approximately 8.750 inches wide, 4.950 inches long, and 2.120
inches high.
[0159] FIG. 35 shows a view of another implementation of a
multi-tier pixelated support structure 3500. The structure 3500
includes a first tier 3502, a second tier 3504 and a third tier
3506. The third tier 3506 supports load bearing elements 3508 that
may vary in shape and size and that may be connected by bridges
3510. The structure 3500 may support sixteen (16) load bearing
elements, for example, although the structure may instead support
more or fewer load bearing elements.
[0160] The first tier 3502 may be formed as a spherical molded
socket 3512. A corresponding spherical ball section 3514 of the
second tier 3504 couples into the socket 3512 as described in more
detail below. The spherical socket 3512 has a center point 3516
near the contact surfaces of the load bearing elements 3508.
Accordingly, as the second tier 3504 moves, the load bearing
elements 3508 move vertically around point 3516 and uncomfortable
horizontal shifting may be reduced.
[0161] Similarly, the second tier 3504 may include molded spherical
sockets 3518. The third tier 3506 may then include a molded
spherical ball section 3520 that couples into the socket 3518. As
shown in FIG. 35, the socket 3518 has a center point 3522 that may
be near the contact surfaces of the load bearing elements 3508. As
the ball section 3520 moves, the load bearing elements 3508 move
vertically around point 3522. As will be shown in more detail
below, the load bearing elements 3508 may also connect to the third
tier 3506 through a ball and socket connection 3524.
[0162] The horizontal spacing of the components of the structure
3500 may be from any given center point may be independently
adjusted. For Example, the ball section 3520 may be located more
closely to the center point 3516 than the ball section 3526. In
that case, the load bearing elements supported by the portion of
the second tier that includes the ball section 3520 provide the
feeling of additional force or pressure with respect to rotation
around the center point 3516. Similarly, because the load bearing
element 3528 is farther than the load bearing element 3530 from the
center point 3532, the load bearing element 3528 has less force or
pressure with respect to rotation around the center point 3532. The
other multi-tiered pixelated support structures may also vary the
relative locations of pivots between tiers in order to configure
the force applied to each load bearing element.
[0163] In FIG. 36, a sectional view of the structure 3500 is
present. The socket 3512 in the first tier 3502 couples to the ball
section 3514 through a bearing 3602. The bearing 3602 may extend up
through a slot 3604 in the ball section 3514 and down through a
perpendicular slot 3606 through the socket 3512. Ribs 3618 may be
included to strengthen the ball section 3514.
[0164] Each slot permits motion of the second tier 3504 along its
length, although stops may be inserted to constrain that motion in
some implementations. In addition, a friction mechanism such as a
rubber O-ring may be placed between the ball section 3514 and the
socket 3512 to provide resistance to gravitational or other forces
that would deflect the structure when no load is applied. The
bearing tabs 3608, 3610 may snap through the slots 3604, 3606 to
retain the bearing 3602 in place. The third tier 3506 may couple to
the second tier 3504 through the same bearing and slot
arrangement.
[0165] A sectional view of the socket connection 3524 is also shown
in FIG. 36. The socket connection 3524 includes a stem 3612 that
terminates in a ball 3614. The load bearing element may then
include a socket 3616 that mates with the ball 3614. The socket
connection 3524 may permit the load bearing elements 3508
significant freedom of motion to comfortably support or conform to
a load.
[0166] FIG. 37 illustrates a bottom view of the multi-tier
pixelated support structure shown in FIG. 35. The bottom view shows
the slot 3606 through the socket 3512 and the bearing tabs 3610
that extend down through the slot 3606. In addition, FIG. 37
illustrates the slots 3702, 3704, and 3706 in sockets 3708, 3710,
and 3712 provided in the second tier 3504. Tabs 3714 for a
spherical bearing that couples a portion of the third tier 3506 to
the second tier 3504 are also shown.
[0167] The load bearing elements 3508 may be formed from
polypropylene, for example. Rigid nylon may be used to form the
tiers 3502-3506. The bearing pieces may be formed from Acetal
material or another self lubricating material.
[0168] FIG. 38 shows exemplary dimensional information for the
multi-tier pixelated support structure 3500. The structure 3500 may
vary widely in size and shape to suit any particular design. The
tiers 3502-3506, load bearing elements 3508, ball and socket
joints, and bearings may be independently sized and shaped. In the
example shown in FIG. 38, the structure 3500 includes sixteen (16)
load bearing elements 3508. The structure is approximately 11.000
inches wide, 7.180 inches long, and 2.972 inches high.
[0169] FIG. 39 shows a side view of a multi-tier pixelated support
structure 3900. The structure 3900 includes a first tier 3902, a
second tier 3904 and a third tier 3906. The third tier 3906
supports load bearing elements 3908. The load bearing elements 3908
may vary in shape, size, and number. Four load bearing elements,
one supported by each of the four support arms in the third tier
3906 are labeled 3922, 3924, 3926, and 3928.
[0170] The structure 3900 may couple together the tiers 3902-3906
using living hinges (three of which are identified as 3910, 3912,
and 3914 in FIG. 39) or in another manner. Support arms may branch
out from each hinge. For example, the first support arm 3916 and
the second support arm 3918 branch out from the hinge 3910.
Alternatively, the support arms may be elastic and deflect under
dynamic load.
[0171] The structure 3900 may also include a base connection 3920.
The base connection 3920 may connect the structure 3900 to an
underlying support structure. The underlying support structure may
define the skeleton for a chair or any other support structure. The
base connection 3920 may include a snap-on interface, bolt or screw
holes, or other type of connection mechanism. One or more
structures 3900 may be attached to the underlying support structure
to form a larger pixelated support surface for the back, seat,
arms, or other area of the body.
[0172] The structure 3900 may be formed from injection molded
polypropylene. Injection molding may be employed for individual
pieces of the structure 3900, including the load bearing elements
3908, tiers 3902-3906, and support arms 3916-3918, or for the
structure 3900 as a whole. Individual pieces may then be snapped,
screwed, glued, or otherwise secured together to form the structure
3900.
[0173] In FIG. 40, a top view 4000 of the structure 3900 is
present. One or more of the load bearing elements 3922-3928 may
include a shaped edge 4010. For example, the shaped edge may be
scalloped to reduce the amount of straight edges between
neighboring load bearing elements. The shaped edges 4010 may
thereby reduce pinching of clothing or skin between the load
bearing elements 3922-3928 as they move in response to an applied
load. FIG. 41 provides a perspective view from the back of the
multi-tier pixelated support structure 3900.
[0174] The structure 3900 may vary widely in shape and size. In one
implementation where the structure 3900 is used to support part of
a body, the structure 3900 may be 10.5 inches tall, and may vary
between 6 inches and 9.5 inches wide. Other dimensions may be
employed, and each load bearing element 3922-3928 may individually
vary in size, shape, dimension, and material. In addition, the
structure 3900 may include more or fewer tiers.
[0175] FIG. 42 shows a side view of a multi-tier pixelated support
structure 4200. The support structure 4200 includes a first tier
4202, a second tier 4204 and a third tier 4206. Each tier may
include support elements. In FIG. 42, the first tier 4202 includes
a first tier support element 4208 and the second tier 4204 includes
the second tier support elements 4210 and 4212. The third tier 4206
may include one or more load bearing elements 4214.
[0176] The first tier 4202 may include curvature in one or more
planes on one or more surfaces. In FIG. 42, the first tier 4202 is
curved in two planes on the lower surface 4216 that contacts the
underlying support structure 4217. The curvature may vary and may
provide additional force or pressure at selected locations over the
structure 4200.
[0177] For example, in FIG. 42, the curvature of the first tier
4202 varies in two directions from the center point 4218. The
center point 4218 may be the tangent point between the first tier
4202 and the underlying support structure 4217 when the support
structure 4200 is unloaded. Center points 4220 and 4222 are also
shown for the support elements 4210 and 4212.
[0178] To the left of the center point 4218, the first tier 4202
may have a first radius, while to the right of the center point
4218, the first tier 4202 may have a second radius. In addition,
the distance between center points 4218-4222 may vary. In FIG. 42,
the distance between the center points 4218 and 4220 is shorter
than the distance between the center points 4218 and 4222.
Additional force or pressure may be given by increasing or
decreasing the distance between center points, or increasing or
decreasing the radius of curvature, or both.
[0179] The lower surface 4216 may include pegs 4224 that interface
with receptacles 4226 in the underlying support structure 4208. In
one implementation, the underlying support structure 4217 may be
peg board or another perforated or dimpled structure that may
accept the pegs 4224. The pegs 4224 may be sized accordingly and in
one implementation may be 0.25 inches in diameter and 0.25 inches
tall.
[0180] The first tier support element 4208 may also include
receptacles that interface with pegs 4228 on the second tier
support elements 4210, 4212. The load bearing elements 4214 may be
secured to the second tier support elements 4210 using a fastener,
snap fit, or other securing mechanism. The load bearing elements
4214 may be elastic or springy to add cushioning during dynamic
loads. Alternatively, the elements 4214 may be implemented as an
additional set of curved rolling surfaces. An elastic band may
secure the second tier support element 4210 or 4212 to the first
tier support element 4208. Similarly, an elastic band may secure
the first tier support element 4208 to the underlying support
structure 4217.
[0181] FIG. 43 shows a top perspective view 4300 of the support
structure 4200. The support structure 4200 and its constituent
parts may vary widely in size, shape, and material. The structure
4200 may be formed from injection molded polypropylene. In one
implementation, the support structure 4200 may be approximately 2
inches tall. The first tier 4202 may be approximately 1 inch thick,
the second tier 4204 may be approximately 0.5 inches thick, and the
third tier 4206 may be approximately 0.5 inches thick.
[0182] The first tier support element 4208 may approximately be 8
inches wide and 8 inches long, the second tier support elements may
approximately be 4 inches wide and 4 inches long, and the load
bearing elements 4214 may be 2 inches wide and 2 inches long. In
FIG. 43, the support structure is shown to accommodate one first
tier support element 4208 supporting four second tier support
elements supporting sixteen load bearing elements 4214. Any other
number of tiers, support elements, and load bearing elements may be
employed.
[0183] FIG. 44 shows a top view of a torsional pixelated support
structure 4400. As shown, the structure 4400 includes four rows
4402, 4404, 4406, and 4408 and four columns 4410, 4412, 4414, and
4416 of load bearing elements, such as the load bearing elements
4404 and 4406. The structure 4400 may include more or fewer rows
4402-4408 and columns 4410-4416. In one implementation, the
structure may be formed from injected molded polypropylene.
[0184] The structure 4400 may vary widely in size. In one
implementation the structure 4400 may be approximately 12.5 inches
wide and approximately 11 inches long. The structure 4400 may be
sized and curved as noted below to cradle, conform to, or otherwise
accommodate any body part, including the spine, arms, legs, or any
other part.
[0185] The structure 4400 shown in FIG. 44 includes 16 sets of load
bearing elements that may be located at intersections of the rows
4402-4408 and columns 4410-4416. Each set may include one or more
interconnected load bearing elements. As shown in FIG. 44, each set
may be formed as a pair of load bearing elements, such as the
element pairs 4418 and 4420. Each element pair may include a first
load bearing element and a second load bearing element connected by
a bar or beam or other section of material. The load bearing
elements and connecting bar for the element pair 4418 are labeled
4422, 4424, and 4426, while the load bearing elements and
connecting bar for the element pair 4420 are labeled 4428, 4430,
and 4432.
[0186] Load bearing elements, or sets of load bearing elements, may
twist or otherwise deflect around a connecting bar. The connecting
bar may operate as a torsional spring. For example, the load
bearing elements 4428 and 4430 may twist in the same or opposite
direction around the connecting bar 4432.
[0187] The length of each load bearing element may be individually
adjusted. Each length may be selected to set the force and pressure
at any particular load bearing element or set of load bearing
elements. As load bearing elements increase in size, the force and
pressure decreases and as the load bearing elements decrease in
size, the force and pressure increases.
[0188] For example, as shown in FIG. 44, the load bearing elements
4428 and 4430 may be smaller than the load bearing elements 4460
and 4462. The load bearing elements 4428 and 4430 may then provide
additional force and pressure with respect to the load bearing
elements 4460 and 4462. As a set, the load bearing elements 4428
and 4430 may twist in one direction (e.g., into or out of the
page), with the set of load bearing elements 4460 and 4462 twisting
in the opposite direction due to the coupling provided by the
connecting bar 4464.
[0189] The sets of load bearing elements 4428 and 4430, and 4460
and 4462 twist around a pivot point 4466 where the connecting bar
4464 couples to the connecting bar 4468. The connecting bar 4468
provides a fulcrum connection to the connecting bar 4466. The force
and pressure provided by the load bearing elements may be tailored
to provide selected support for any body part, or according to
other criteria.
[0190] As another example, a set of two pairs of load bearing
elements is labeled 4434 in FIG. 44. In the set 4434, the element
pair 4418 is connected to an adjacent element pair 4435 by a
connecting bar 4436. The connecting bar 4436 may connect between
the two connecting bars 4426, 4438 that couple together the
individual load bearing elements. The sets of load bearing elements
4418, 4435 may twist or otherwise deflect around the connecting bar
4442, which provides a fulcrum connection to the connecting bar
4436.
[0191] Similarly, multiple sets of load bearing element sets may
connect together through a connecting bar. The set 4434 connects to
the adjacent set 4440 through the connecting bar 4442. The
connecting bar 4442 for the larger set of four load bearing element
sets may connect between the connecting bar 4436 and the connecting
bar 4444 for the next smaller sets of two load bearing element
sets. Each set 4434, 4440 may then twist or otherwise deflect
around the connecting bar 4442.
[0192] Load bearing elements may be grouped together and
interconnected in incrementally larger sets. For example, FIG. 44
shows a first group 4446 of four sets of load bearing elements
coupled together to an adjacent group 4448 of four sets of load
bearing elements through a connecting bar 4450. The connecting bar
4450 may connect between the connecting bars 4452 and 4454 for the
smaller sets of four load bearing elements. Similarly, the
connecting bar 4456 may then connect adjacent groups of eight sets
of load bearing elements by coupling between the connecting bars
4450 and 4458.
[0193] A bottom view of the structure 4400 is present in FIG. 45.
The bottom view shows the structure 4400 curved in two planes. The
curvature may match the curvature of the back, legs, or another
body part. The curvature in any plane is optional.
[0194] The connecting bars may perpendicularly connect between
other connecting bars, or may connect at other angles. Each
connecting bar may flex as well as twist to enhance spring action.
Each connecting bar may also vary in depth or width to increase its
stiffness. As the connecting bars couple together increasing
numbers of load bearing elements, each connecting bar may also
increase in size to accommodate the increasing load. For example,
the connecting bars between individual load bearing elements (e.g.,
connecting bar 4426) may be the shallowest, while connecting bars
between sets of eight sets of load bearing elements (e.g.,
connecting bar 4456) may be the deepest.
[0195] Securing tabs 4502 and 4504 may be added to a connecting
bar. Screws or other fasteners may pass through the securing tabs
4502 and 4504 to secure the structure 4400 to an underlying frame
or spine. Alternatively, the securing tabs 4502 and 4504 may
snap-fit into a mating connector on the frame or spine. The
structure 4400 may couple to the frame or spine in other manners at
other points, however.
[0196] The connecting bars may vary in size and thickness. The
thickness may vary according to the load borne by any given portion
of the connecting bar. As an example, FIG. 45 shows that the
connecting bar 4454 includes a left branch 4506 and a right branch
4508. The left and right branches 4506, 4508 increase in thickness
as they near the connecting bar 4450 where greater loads are
expected. The left and right branches 4506, 4508 decrease in
thickness away from the connecting bar 4450 toward the individual
load bearing element pairs 4512, 4514, 4516, and 4518 where
relatively lighter loads are present.
[0197] FIG. 49 shows that a connecting bar (e.g., the connecting
bar 4456) in the support structure 4400 may run along a supporting
surface 4902 at a contact point 4904. The supporting surface 4902
may be part of an underlying support structure defining a chair or
other object. The connecting bar and/or the supporting surface may
be flat, curved, or may have other shapes. For example, the
connecting bar may have a selected radius (e.g., 3 inches), and the
supporting may have a larger (e.g., 4 inches) or smaller radius. As
another example, the connecting bar may be flat, and the supporting
surface may be curved in a convex or concave manner.
[0198] The contact point 4904 moves along the supporting surface
4902 in accordance with the position of the load on the structure
4400. For example, as the load on the structure 4400 shifts left,
the contact point 4904 may shift left. The curvature or lack of
curvature in the connecting bar and/or the supporting surface may
be selected to establish a force vector through the contact point
in a given direction. In the context of a seat, for example, the
force vector may be selected so that the occupant is pushed back
into the chair when the occupant load is at any given position in
the structure 4400. Alternatively, the force vector may be selected
so that the occupant is pushed out of the chair when the occupant
load moves far enough forward along the structure 4400.
[0199] Returning again to FIG. 44, the face of one or more load
bearing elements may be contoured. In other words, the interface
between a load bearing element and the skin may be selected to
impart any desired feel to the load bearing elements. In addition,
the connection bars shown in the structure 4400 may take other
forms, for example a form that permits the load bearing elements or
sets of load bearing elements to translate.
[0200] FIG. 50 shows a torsional support structure 5000 that
employs a translational coupling 5002 that may be employed between
load bearing elements 5004 and 5006. The translational coupling
5002 may include spring elements 5008 and 5010. The spring elements
5008 and 5010 may include an undulating shape (such as the U-shape
shown in FIG. 50) that permits the load bearing elements 5004 and
5006 to translate in the direction shown by the arrows 5012 and
5014. The translational coupling 5002 is not limited to any
particular shape or form, however, and may be implemented in other
manners.
[0201] Through the translational coupling 5002, the load bearing
elements may move in the plane of the skin. Accordingly, as the
skin is stretched or compressed (e.g., when the lumbar spine is
flexed) the load bearing elements may move without shearing on the
skin. FIG. 51 shows a perspective view of the torsional support
structure 5000 and translational coupling 5004.
[0202] In FIG. 46, a side view of a multi-bar tiered pixelated
support structure 4600 is present. The structure 4600 may include
two columns of four load bearing elements. For of the load bearing
elements are shown and are labeled 4602, 4604, 4606, and 4608.
Three tiers 4610, 4612, and 4614 may support the load bearing
elements. The structure 4600 may be made of polypropylene in an
injection molding process.
[0203] A portion 4616 of the structure 4600 may couple to an
underlying frame or other structural member through bolts, screws,
or other fasteners, through a snap-fit, or in other ways. The
structural member may be a portion of a chair frame corresponding
to the lower back, for example. The load bearing elements 4602-4608
may then support the lower back as described in more detail below.
In general, it is noted that more or fewer load bearing elements
and/or tiers may be employed, and that the structure 4600 may be
tailored to match any body part by individually adjusting the size,
shape, or stiffness of the structure's components.
[0204] The tiers 4610-4614 may include one or more four bar
connections. In the tier 4610, four sets of four bar connections
are present. In the first set, the living hinges 4618 and 4620
emerge as individual members from the first tier base 4626. Each
living hinge may include two narrowed portions that operate as
hinge points. The hinge points for the living hinge 4618 are
labeled 4660 and 4662. Similarly, the second set of 4-bar
connections includes the hinge points around the living hinges 4622
and 4624. The third and fourth sets of four bar connections emerge
from the first tier base 4636. The third and fourth sets are formed
by the living hinges 4628, 4630, 4632, and 4634.
[0205] In the second tier 4612, the living hinges 4638, 4640, 4642,
and 4644 emerge from the second tier base 4646. The living hinges
4638 and 4640 implement a four bar connection to the first tier
base 4626, and the living hinges 4642 and 4644 implement a four bar
connection to the first tier base 4636. Similarly, in the third
tier 4614, the two living hinges 4648 and 4650 emerge from the
third tier base 4652 and implement a four bar connection to the
second tier base 4646.
[0206] In the third tier 4610, the living hinges may branch into
one or more support fingers connected to load bearing elements. For
example, the living hinge 4618 branches out into the first support
finger 4656 and the second support finger 4658.
[0207] FIG. 46 shows that the bases 4626, 4636, and 4646 may be
formed in a V-shape. The V-shape occupies less space than a
straight connection and may contribute to the compactness of the
structure 4600. In one implementation for a lumbar support, the
structure 4600 may be approximately 10 inches wide and
approximately 6 inches tell. The load bearing elements may be
approximately 4.5 inches wide and approximately 1.3 inches tall.
The total thickness of the support structure 4600, excluding the
load bearing elements 4602-4608 and base 4616 may be approximately
3.2 inches. In one implementation, they may be 0.030'' thick and
may narrow down at either end, but may vary widely depending on the
implementation.
[0208] The living hinges may be individually oriented to impart
selected rotational characteristics to the load bearing elements
4602, 4604, 4606, and 4608. As one example, the living hinges 4642
and 4636 are angled to set a center of rotation 4654 for the load
bearing elements 4606 and 4608. For lumbar support, the centers of
rotation may be set at any distance at or above the surface of the
load bearing elements. In particular, the centers of rotation may
be selected such that the load bearing elements 4606 and 4608 move
with the skin, rather than along the skin.
[0209] FIG. 47 shows a perspective view of the structure 4600. The
structure 4600 includes a first column 4702 and a second column
4704 of load bearing elements (e.g., elements 4602-4608). The
structure 4600 may also include pivot points 4706, described in
more detail below with respect to FIG. 48.
[0210] In FIG. 48, a top view of the support structure 4600 is
shown. Three pivot points are present, including the central pivot
point 4802, and the column pivot points 4804 and 4806. The pivot
points 4802-4806 may be formed as a narrowed section of material
and may be thickness controlled to impart any desired amount of
stiffness to the pivot point.
[0211] The columns 4702 and 4704 may pivot together on the central
pivot point 4802. In addition, the first column 4702 may pivot on
the pivot point 4806 independently of the second column 4704.
Similarly, the second column 4704 may pivot on the pivot point 4804
independently of the first column 4702. The structure 4600 thereby
responds to and provides ergonomic or balanced support for loads
placed on the structure 4600.
[0212] FIG. 52 shows a multiple tier pixelated support structure
5200. The structure 5200 may include first-tier load bearing
elements such as those labeled 5202, 5204, 5206, 5208, 5210, and
5212. In the implementation shown in FIG. 52, the load bearing
elements 5202-5212 are triangular. Triangular load bearing elements
may provide enhanced conformance to the body part that the load
bearing elements support, in comparison with other load bearing
element shapes. However, other load bearing element shapes may also
be used in conjunction with or instead of the triangular
shapes.
[0213] The load bearing elements 5202-5212 may form groups. For
example, the structure 5200 includes hexagonal load bearing element
groups, three of which are labeled 5214, 5216, and 5218. Living
hinges 5220 may connect individual load bearing elements to form a
load bearing surface from one or more load bearing elements and/or
one or more groups.
[0214] The load bearing surface may take many different shapes and
sizes. As examples, the load bearing surface may extend in two
dimensions to provide a chair seat, or may extend primarily in one
dimension as a linear strip of load bearing elements. The load
bearing surface may also take on form in three dimensions. For
example, the load bearing surface may take a convex shape. The
convex shape may match the body shape of a relatively small chair
occupant. The living hinges 5220 may flatten to accommodate
relatively large chair occupants on the load bearing surface. As
the surface adapts to the contour of the sitter's buttocks, the
living hinges 5220 will expand and flatten.
[0215] The structure 5200 may also include load bearing element
support arms such as rockers connected to the load bearing
elements. Three of the rockers are labeled 5222, 5224, and 5226.
The rockers may connect through a rocker connection such as a
shockmount to a second-tier support arm. One of the rocker
connections is labeled 5228 and one of the second-tier support arms
is labeled 5230 in FIG. 52. The rocker connections 5228 may accord
the rockers a lower spring rate than the load bearing elements, may
take vertical load compressively, and may allow angular rocking
with force feedback. In one implementation, the rocker connections
5228 are ball and socket joints.
[0216] The rockers may provide support to any one or more of the
load bearing elements. In FIG. 52, the rockers provide support to
three of the six load bearing elements in each hexagonal group. For
example, the load bearing elements 5202, 5206, and 5210 are
directly supported by rockers, while load bearing elements 5204,
5208, and 5212 are supported through living hinges to adjacent load
bearing elements 5202, 5206, and 5210.
[0217] The load bearing elements may attach to the rockers in many
ways. The load bearing elements may attach through a snap fit
joint, such as a ball and socket joint, through a fastener, or in
other manners. The second tier support arms 5230 may be straight or
may include curvature, for example, to meet manufacturability
process constraints. The second tier support arms 5230 and rockers
may be a single injection molded part or may be individually
formed.
[0218] One or more of the second-tier support arms may emerge from
a support arm connection such as the connection labeled 5232. The
support arm connections 5232 may be implemented as noted above with
regard to the rocker connections 5228. The support arm connection
be part of a third-tier support arm, such as the third-tier arms
labeled 5234 and 5236.
[0219] The hexagonal load bearing element groups 5214, 5216 and
5218 form a tri-hex load bearing surface that is supported by the
second tier. Specifically, second tier support arms that emerge
from a common support arm connection may each support one of the
load bearing element groups. Accordingly, eighteen load bearing
elements may perform load balancing at the same rate. The center of
the tri-hex surface may be located under pre-selected anatomical
areas, such as the ischial tuberosites, under the thigh centerline,
or other areas and may keep forces balanced at that point. The
third-tier support 5238 may then proportion loads between or among
the functional areas. The third tier support 5238 may vary the
ratio of the length of its arms to give proportionally higher loads
in any given location.
[0220] As shown in FIG. 52, the third-tier support arms 5234 and
5236 may be part of a third-tier support 5238. The third-tier
support 5238 may include a coupling 5240. The coupling 5240 may
connect to structural elements such as pins, rods, or other
fasteners to connect the structure 5200 to adjacent structures, for
example to extend the load bearing surface in a given
direction.
[0221] The third-tier support 5238 may be H-shaped and may be a
separately molded part. The H-shape support 5238 includes the
support arms 5234 and 5236 connected by a bar on which the coupling
5240 may be located. The third-tier support 5238 may connect
through the bar to an underlying support frame through pinning, for
example with a steel pin, a molded snap fit connection, a fastener,
or other connection.
[0222] One or more of the tiers may alone or in combination with
other tiers provide curvature to the load bearing surface. The
curvature is self-tailoring and adapts to the body part to the
supported by the load bearing surface. For example, a load bearing
surface that forms a chair seat have a curvature consistent with
the buttocks.
[0223] The elements shown in FIG. 52 may be formed through an
injection molding process, a vacuum or heat forming process, or by
other processes. The elements may be formed from polypropylene,
thermoplastic elastomers, Hytrel.TM. material, polyethylene,
polyamide (with or without fillers), glass filed nylon, fiberglass,
spring steel, or other materials. Each element may be adjusted in
size, shape, dimension, and/or material to impart a selected
stiffness to any portion of the load bearing surface. The load
bearing surface may thereby provide tailored support for selected
body parts across the surface.
[0224] A layer of material may be placed over the top of the load
bearing elements. The material may be a knit fabric or other
interface between the load and the load bearing elements.
[0225] FIG. 53 shows an expanded view of the rockers 5222, 5224,
and 5226. The rocker connection 5228 and a portion of the support
arm 5230 is also shown. The rockers 5222, 5224, and 5226 connect to
the load bearing elements through connection points 5302, 5304, and
5306. The connection points 5302, 5304, and 5306 may implement a
snap fit connection or joint, such as a ball and socket joint, may
be a fastener, or may provide a connection in other manners.
[0226] The rockers 5222, 5224, and 5226 may provide approximately
one inch of separation between the load bearing element connection
points 5302, 5304, and 5306. The triangular load bearing elements
5202-5212 may correspondingly be approximately 1 inch on a side.
Other sizes and distances may also be used.
[0227] The rockers 5222, 5224, and 5226 and/or the support arms
5230 may be formed from a glass filed nylon or Polybutylene
Terephtalate (PBT) material. The rocker connection 5228 (and
support arm connections 5232) may be a shockmount formed from Hytel
material, Santoprene material, or other material. The rocker
connection 5228 may be implemented with a softness between a Shore
D 35 and a Shore A 80-95 softness. Other softnesses may be
selected.
[0228] FIG. 54 shows a bottom view of a torsional pixelated support
structure 5400. The structure 5400 may form all or part of a chair
seat or other support structure. The structure 5400 includes load
bearing elements, four of which are labeled 5402, 5404, 5206, and
5208. The load bearing elements may be formed and interconnected as
described above with reference to FIGS. 44 and 45. As will be
described in more detail below, however, one or more connecting
bars may be replaced with connecting bars with a longer effective
length.
[0229] In the structure 5400, the connecting bar between pairs of
load bearing elements may include a support post. The support post
5410 may extend away form the load bearing elements and may provide
a mechanical stop to displacement of the load bearing elements.
Alternatively, a supporting structural member behind the structure
5400 may include stops that extend up toward the structure 5400.
The support post 5410 extends from the connecting bar between the
load bearing elements 5402 and 5404. Support posts for neighboring
pairs of load bearing elements are labeled 5412, 5414, and
5416.
[0230] In the implementation shown above, the connecting bars
(e.g., connecting bar 4436) between pairs of load bearing elements
were substantially straight. The connecting bars, for example those
between pairs of load bearing elements, may take other shapes at
any tier, however. As shown in FIG. 54, the connecting bars in the
second and third tiers are S-shaped.
[0231] Four of the S-shaped bars in the second tier are labeled
5418, 5420, 5422, and 5424. The S-shaped bars 5418-5424 may connect
together at one end, and may connect at the other end to the
support posts 5410-5416. In a manner analogous to the connect bar
4442, additional S-shaped bars may connect together multiple pairs
of load bearing elements in the second tier. For example, the
S-shaped bar 5426 connects between the S-shaped connecting bars
5412 and 5416 to connect together two pairs of load bearing
elements. Similarly, the S-shaped bar 5428 connects between the
S-shaped connecting bars 5422 and 5424 to connect together the two
pairs of load bearing elements 5402-5408.
[0232] At the third tier, S-shaped bars may also connect together
larger sets of load bearing elements. As shown in FIG. 54, the
S-shaped bar 5430 connects four pairs of load bearing elements
5432. The S-shaped bar 5434 connects four pairs of load bearing
elements 5436.
[0233] The S-shape may provide an effectively longer connecting
bar. In FIG. 54, the S-shaped bars are folded back on themselves
and consume approximately the same amount of space as a relatively
straight connection bar, yet are approximately three times longer.
The additional length increases the amount of flexing and
deflecting in the connecting bars.
[0234] Each connecting bar may have an individually selected cross
section or height, shape, material, or other characteristics. The
height of a connection bar may vary along its length (e.g., by
approximately 0.010 inches). The thickness of each connection bar
may increase between tiers (e.g., by approximately 0.020 inches).
The cross section may be increased or decreased, for example, to
stiffen or loosen the connecting bar.
[0235] In one implementation, the S-shaped bars in the second tier
(e.g., the connection bar 5418) may be 0.090 inches thick, and may
increase from 0.375 inches to 0.475 inches in height along their
length. The height of the S-shaped bars in the third tier (e.g.,
the connection bar 5430) may be 0.110 inches thick and may increase
from 0.475 inches in height to 0.575 inches in height along their
length.
[0236] The structure 5400 may include mounting points. The mounting
points may connect to an underlying frame or other structure using
fasteners, a snap-fit, an interference fit, or in other manners.
Three mounting points 5438, 5440, and 5442 are shown.
[0237] The mounting points may establish independent pixelated
support structures through their connections to the support
structure 5400. For example, the portion of the pixelated support
structure 5400 between the mounting points 5438 and 5440 may move
and react independently from the portion of the pixelated support
structure 5400 between the mounting points 5440 and 5442.
Accordingly, a single structure 5400 may react as multiple
independent support structures.
[0238] In the third tier, S-shaped connection bars may couple the
load bearing elements and second tier to the mounting points. In
FIG. 54, for example, the S-shaped connection bar 5444 connects the
S-shaped connection bars 5430 and 5434 to the central mounting
point 5440. The S-shaped connection bar 5446 connects the S-shaped
connection bars 5430 and 5434 to the peripheral mounting point
5442.
[0239] The structure 5400 may include a peripheral support 5448.
The support 5448 may provide a connection point for a fabric or
other covering for the structure 5400. The size and shape of the
support 5448 may vary widely. In one implementation, the support
5448 is 0.75 inches wide and 0.09-0.10 thick. The support 5448 may
connect to the structure 5400 through connection tabs 5450 to one
or more load bearing elements. Alternatively or additionally, the
support 5448 may connect to the structure 5400 through a connection
5452 to a mounting point, such as the mounting point 5440.
[0240] Alternatively, the support may include bellows, folds, or
other deformable structures 5454. The deformable structures 5454
may provide a degree of flexibility in the support 5448. In one
implementation the deformable structures 5454 may be aligned with
the space between one or more load bearing elements in a pair.
[0241] One or more of the S-shaped connecting bars may include
webbing in one or more locations. The webbing may vary in thickness
between implementations, and may be, for example, approximately
0.025 inches thick. For example, the connecting bar 5434 includes
webbing 5456 and 5458 between each fold of the connecting bar 5434.
The webbing may be centrally vertically located between the folds
in the connecting bars. The webbing may help prevent lateral
bending of the load bearing elements.
[0242] In other embodiments, the bottom tier of S-shaped connection
bars may have a curved rolling surface. The rolling surfaces may be
designed to permit rolling motion in one or more planes. For
example, the rolling surfaces may permit left to right rolling
motion.
[0243] The structure 5400 may be fabricated through a molding
process, for example. The load bearing elements, connection bars
between the load bearing elements, and support 5448 may be formed
in a first injection mold. The lower tiers may be formed in a
second injection mold. A snap fit, interference fit, fastener or
other connection may be made between the first and second molded
portions to form the structure 5400.
[0244] FIG. 55 shows a bottom perspective view 5500 of a torsional
pixelated support structure. The perspective view 5500 (and side
view 5800) shows that the mounting points may be formed from a
triangular truss structure. The mounting points may be formed in
other manners, however. FIG. 56 shows an enlarged view 5600 of a
portion of the support structure 5400. FIG. 57 shows a side view
5700 of the support structure 5400. FIG. 58 shows a side view 5800
of the support structure 5400.
[0245] FIG. 59 shows triangular load bearing elements 5902, 5904,
5906, 5908, 5910, and 5912 arranged in a hexagonal set 5914. The
load bearing elements 5902-5912 are shown as equilateral triangles
approximately 3 inches on a side. However, the load bearing
elements 5902-5912 may vary widely in size, shape, and material. In
other implementations, the load bearing elements 5902-5912 may be
0.5-1.5 inches on a side, for example approximately 1 inch on each
side. The load bearing element size and shape may vary across any
support structure that incorporates the load bearing elements
5902-5912, for example to tailor support to a specific body part.
The load bearing elements may be formed from polypropylene,
thermoplastic elastomers, Hytrel.TM. material, polyethylene,
polyamide (with or without fillers), glass filed nylon, fiberglass,
or other materials.
[0246] FIG. 60 shows a bottom view of a pixelated support structure
6000 that incorporates hexagonal sets of the load bearing elements.
Three hexagonal sets are labeled 6002, 6004, and 6006. The
hexagonal set 6002, for example, includes the load bearing elements
6008, 6010, 6012, 6014, 6016, and 6018.
[0247] As shown in FIG. 60, the load bearing elements may be
connected together to form load bearing surfaces. The load bearing
surface may include injected molded sections that define multiple
connected load bearing elements. One or more bridges between load
bearing elements may permit the load bearing elements to twist or
flex (e.g., an approximately flat bar bridge), to displace from one
another (e.g., a bar connection with a U-shape or undulation out of
the plane of the load bearing elements), or permit the load bearing
elements freedom of motion or rotation in other directions or along
other axes. Alternatively, one or more of the bridges may be
substantially stiff and may hold the load bearing elements in place
without rotation or translation.
[0248] Alternatively or additionally, one or more individually
formed load bearing elements may be connected through individually
formed bridges between the load bearing elements. For example, the
bridge 6020 connects the load bearing elements 6008 and 6010. The
bridge 6020 may be located approximately half way along one edge of
each load bearing element 6008, 6010, although other locations are
also suitable. The bridges may be secured to the load bearing
elements using fasteners such as screws, bolts, interference fits,
snap fits, or other securing mechanisms.
[0249] The bridge 6020 may take many shapes and forms to provide
any desired freedom of movement or flexion to the load bearing
elements. For example, the bridge 6020 may include an approximately
flat connection between each load bearing element to prevent load
bearing elements from separating from one another. Alternatively,
the bridge 6020 may include a U-shape, undulation, or other
displacement of material between load bearing elements that permits
the load bearing elements to displace away from one another.
[0250] The load bearing surface may include multiple tiers of
support elements, including the load bearing elements as a first
tier. FIG. 61 shows a perspective view of a portion of a second
support tier and a portion of a third support tier. As shown in
FIG. 61, the second tier of support elements may include connection
bars 6102 between load bearing elements (e.g., between the load
bearing elements 6104 and 6106). The connection bars 6102 may be
vertically displaced from the load bearing elements by shockmounts
6108.
[0251] The connection bars 6102 may be made from spring steel to
impart substantially stiffness to the connection bar.
Alternatively, one or more connection bars 6102 may be made from
nylon, or other flexible materials. The connection bars may be
secured to the shockmounts 6108 through a screw, bolt, snap fit, or
other fastener. Similarly, the shockmounts 6108 may be secured to
the load bearing elements 6104, 6106 through a screw, bolt, snap
fit, threaded connection, or other fastening mechanism. In other
implementations, the shockmounts 6108 may be implemented as
injected molded ball and socket joints.
[0252] The third support tier may include conical springs 6110,
cantilever springs, or other support elements connected to the
first tier. The third support tier may connect to an underlying
frame. The underlying frame may define a chair seat, chair back, or
any other load bearing structure.
[0253] The multiple tier load bearing surface shown in FIG. 60
provides support over substantially all of its surface. As an
individual sits on the surface, multiple support elements in the
second and third tiers take up the load and provide support. For
example, the conical springs, located at the centers of the
hexagonal sets, assist neighboring conical springs to take up loads
that are centered between the springs.
[0254] The pixelated support elements and structures may be
employed in a wide range of designs for supporting the body,
including seats, backrests, mattresses, and the like. The pixelated
support elements and structures provide enhanced ergonomic body
support structures that may be adapted to provide excellent fit and
comfort tailored to individual body parts, as well as healthy
support for the body, across a wide range of individual body
types.
[0255] It is therefore intended that the foregoing detailed
description be regarded as illustrative rather than limiting, and
that it be understood that it is the following claims, including
all equivalents, that are intended to define the spirit and scope
of this invention.
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