FIELD OF THE INVENTION

The present application relates generally to a body support structure such as a chair, and more specifically to a body support structure including one or more lattice structures.

BACKGROUND

Body supporting structures, including for example, office chairs, vehicular and aircraft seating, sofas, beds and other pieces of furniture, are typically configured with internal or external support frames having hard contact points. For example, seats and backrests may be made with a resilient membrane or shell structure, which are typically supported by a rigid, peripheral frame surrounding the membrane or shell structure. The frame presents hard contact points, precludes flexing of the backrest or seat at the periphery thereof, and may also prevent twisting, or torsional movement, about a longitudinal axis of the backrest or seat. In other chairs, the backrest or seat may be configured with a rigid, central spine allowing for some twisting about a longitudinal axis, but with the connection of the spine to the body support member producing hard, contact points. In yet another type of chair, the backrest or seat may be configured with a rigid shell, which supports a cushion or other resilient body support member.

In many of these conventional seating structures, the rigidity of the frame or shell limits the ability of the body support structure to flex and support the body of the user as the user moves within the seating structure. Moreover, the hard contact points, or lack of flexibility at the edge of the seating structure, combined with the restrictions imposed by the frame, spine and/or rigid shell, limit the comfort and ergonomic responsiveness of the seating structure.

In addition, conventional chairs typically include multiple assemblies and parts, including for example one or more backrests, seats, tilt controls, armrests, pneumatic column/springs, and the like, each of which must be individually assembled, and then collectively assembled into a final product configuration. Often, subassemblies are made at remote locations, or by outside vendors, which requires additional shipping, inventory and transportation costs, which may be exacerbated by relatively heavy metal parts. For example, a convention tilt control may include dozens of parts, including various metal parts that must be stamped or cast, which are then assembled using various mechanical fasteners or welding. The manufacturing and assembly process may involve complex and expensive tooling, which is difficult to modify and adapt to other assemblies.

SUMMARY

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

In one aspect, one embodiment of a body support structure includes a plurality of spaced apart support members defining opposite first and second surfaces, wherein adjacent support members define openings between sides of the adjacent support members. A plurality of spaced apart base members define opposite first and second surfaces, wherein the first surfaces of the base members face toward and are spaced apart from the second surfaces of the support members such that the plurality of support members and the plurality of base members define a space therebetween. Each of the base members underlies at least portions of the openings defined by at least two adjacent support members, and adjacent base members define openings between sides of the adjacent base members. A plurality of connectors extend across the space and connect each base member with the at least two adjacent support members. Each connector defines a first acute angle relative to the second surface of the respective support member and a second acute angle relative to the first surface of the base member.

In yet another aspect, one embodiment of a body support structure includes a field array having a plurality of spaced apart support members arranged in a plurality of rows and a plurality of columns. Each of the rows has the same number (n1) of support members, and each of the columns has the same number (n2) of support members. At least one of the rows has a first width and at least another one of the rows has a second width, wherein the first and second widths are different. At least one of the columns has a first length and at least another one of the columns has a second length, wherein the first and second lengths are different. A perimeter array defines a closed ring surrounding the field array. The perimeter array includes first and second rows of spaced apart support members connected to opposite outermost end rows of the field array, and first and second columns connected to opposite outermost end columns of the field array. The first and second rows and the first and second columns of the perimeter array are connected, and wherein the first and second rows of the perimeter array comprise n1 support members and wherein the first and second columns of the perimeter array comprise n2 support members. The support members in the field array and perimeter array are connected.

In yet another aspect, one embodiment of a body support structure includes a field array having a plurality of spaced apart support members arranged in a plurality of rows and a plurality of columns, wherein each of the rows has n1 support members, and wherein each of the columns has n2 support members. The outermost periphery of the field array has n3 support members, wherein n3=2*n1+(2*(n2−2)). At least one of the rows has a first width and at least another one of the rows has a second width, wherein the first and second widths are different. At least one of the columns has a first length and at least another one of the columns has a second length, wherein the first and second lengths are different. A perimeter array defines a closed ring surrounding and connected to the field array. The perimeter array includes first and second rows of spaced apart support members connected to opposite outermost end rows of the field array, and first and second columns connected to opposite outermost end columns of the field array. The first and second rows and first and second columns of the perimeter array have n4 support members, wherein n4=(2*n2)+(2*n1). The support members in the field array and perimeter array are connected.

In yet another aspect, one embodiment of a body support structure includes a structural lattice structure having a first stiffness, and a compressive lattice structure supported by the structural lattice structure and having a second stiffness less than the first stiffness. The compressive lattice structure is compressible in response to a first normal force applied thereto. A skin lattice structure is supported by the compressive lattice structure, wherein the skin lattice structure is resistant to shear deformation in response to a second normal force applied thereto, and wherein the skin lattice structure is expandable in a direction transverse to the second normal force applied thereto in response to the second normal force being applied thereto.

In yet another aspect, one embodiment of a body support structure includes a base structure, a body support member and a strut. The strut includes spaced apart first and second end portions coupled to the body support member and base structure respectively and an intermediate compressive lattice structure connected to the first and second end portions. The first and second end portions are moveable between a nominal position and a compressed position, wherein the compressive lattice structure is compressible between a nominal configuration and a compressed configuration corresponding to the nominal and compressed positions. The compressive lattice structure applies a biasing force to the first and second end portions when in the compressed configuration.

In yet another aspect, one embodiment of a body support structure includes a base structure and a body support member coupled to the base structure. At least one of the base structure and body support structure includes a lattice structure having an integrated kinematic feature. In various embodiments, the integrated kinematic feature may include a movement limiter, locking system, component connector and/or biasing member.

In yet another aspect, one embodiment of a method of manufacturing any of the body support structures disclosed herein includes forming the structural lattice structure, the compressive lattice structure and the skin lattice structure by additive manufacturing. In one embodiment, the additive manufacturing is performed by 3-D printing. In one embodiment, the method includes integrally forming the structural lattice structure, compressive lattice structure and skin lattice structure during a single 3-D printing operation.

In yet another aspect, one embodiment of a body support structure includes a plurality of spaced apart support members defining opposite first and second surfaces, wherein adjacent support members define openings between sides of the adjacent support members. A plurality of spaced apart base members define opposite first and second surfaces, wherein the first surfaces of the base members face toward and are spaced apart from the second surfaces of the support members such that the plurality of support members and the plurality of base members define a space therebetween. Each of the base members underlies at least portions of the openings defined by at least two adjacent support members, and adjacent base members define openings between sides of the adjacent base members. A plurality of connector legs extend across the space and connect each base member with the at least four adjacent support members, and with each support member connected to at least four adjacent base members. At least some of the connector legs have a different length than other connector legs, wherein the spaces between at least some of the connected support members and base members are different from the spaces between other connected support members and base members. A first region includes longer connector legs connecting the base members and support members, while a second region includes shorter connector legs connecting the base members and support members. The first and second regions may have different stiffnesses, for example with the second region being stiffer than the first region.

In one embodiment, an edge portion is connected to and surrounds the base members and support members. In one embodiment, the edge portion may be tapered.

The various embodiments of body support structures and methods provide significant advantages over other body support structures, and methods for the manufacture and assembly thereof. For example and without limitation, the body support structures provides an overall compliant structure, which may be configured with a soft interface portions, for example at outer peripheral edges and along a front, thigh-supporting portion. Moreover, changes in the configuration of one or more components, or the entire chair, may be made quickly and easily through software/programming changes, rather than by complex and expensive retooling. Indeed, the need for tooling may be eliminated entirely. Shipping costs may be greatly reduced as the entire body support structure may be made at a single location, with such manufacturing sites being strategically located at various geographic locations proximate the end user or point-of-sale/delivery.

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

