BACKGROUND OF THE I NVENTION

[0001] The present invention relates to a chair assembly, and in particular to an office chair assembly comprising a vertically adjustable, articulating headrest assembly.

BRIEF SUMMARY OF THE INVENTION

[0002] One aspect of the present invention is to provide a seating unit comprising a seat assembly adapted to support a seated user thereon, a back assembly extending upwardly from the seat assembly and ada pted to support a seated user, and a headrest assembly adapted to support a head of a seated user. The headrest assembly comprises a frame assembly including a pair of vertically spaced frame portions and a pair of horizontally spaced frame portions, wherein the frame portions cooperate to form an open space therebetween, and wherein at least one of the frame portions includes a plurality of first alignment features, and a thermoplastic elastomeric cover member stretched between at least one of the pair of vertically spaced frame portions and the pair of horizontally spaced frame portions, wherein the cover member includes a plurality of second alignment features that cooperate with the first alignment features to align a cover member with the frame assembly.

[0003] These and other features and advantages of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Fig. 1 is a front perspective view of a chair assembly embodying the present invention;

[0005] Fig. 2 is a rear perspective view of the chair assembly;

[0006] Fig. 3 is a side elevational view of the chair assembly showing the chair assembly in a lowered position and in a raised position in dashed line, and a seat assembly in a retracted position and an extended position in dashed line;

[0007] Fig. 4 is a side elevational view of the chair assembly showing the chair assembly in an upright position and in a reclined position in dashed line; [0008] Fig. 5 is an exploded view of the seat assembly;

[0009] Fig. 6 is an enla rged perspective view of the chair assembly with a portion of the seat assem bly removed to illustrate a spring support assem bly;

[0010] Fig. 7 is a front perspective view of a back assembly;

[0011] Fig. 8 is a side elevationa l view of the back assembly;

[0012] Fig. 9A is a n exploded front pe rspective view of the back assembly;

[0013] Fig. 9B is an exploded rea r perspective view of the back assembly;

[0014] Fig. 10 is an enla rged perspective view of an a rea X, Fig. 9A;

[0015] Fig. 11 is an enla rged perspective view of an a rea XI, Fig. 2;

[0016] Fig. 12 is a cross-sectional view of an upper back pivot assembly taken along the line XI I-XI I, Fig. 7;

[0017] Fig. 13A is a n exploded rea r perspective view of the upper back pivot assembly;

[0018] Fig. 13B is a n exploded front perspective view of the upper back pivot assembly;

[0019] Fig. 14 is an enla rged perspective view of the area XIV, Fig. 9B;

[0020] Fig. 15A is an enlarged perspective view of a comfort member a nd a lum bar assembly;

[0021] Fig. 15B is a rea r perspective view of the comfort member and the lumbar assembly;

[0022] Fig. 16A is a front perspective view of a pawl mem ber;

[0023] Fig. 16B is a rear perspective view of the pawl member;

[0024] Fig. 17 is a partia l cross-sectional perspective view along the line XVI I I-XVI I I, Fig.

15B;

[0025] Fig. 18 is a perspective view of an alternative embodiment of the cha ir assembly including a headrest assembly;

[0026] Fig. 19 is a side elevational view of the a lternative embodiment of the chair assembly, showing the headrest at lowered and raised positions;

[0027] Fig. 20 is a side elevational view showing the headrest at a forward and a rea rwa rd a rticulated position;

[0028] Fig. 21 is an exploded front perspective view of the back assembly;

[0029] Fig. 22 is an exploded rea r perspective view of the back assembly;

[0030] Fig. 23 is an exploded perspective view of the headrest assembly; [0031] Fig. 24 is a cross-sectional view of the headrest assembly taken along the line XXIV

- XXIV, Fig. 21;

[0032] Fig. 25 is a cross-sectional view of the headrest assembly taken along the line XXV

- XXV, Fig. 21;

[0033] Fig. 26 is a perspective view of the alternative embodiment of the chair assembly;

[0034] Fig. 27 is a front elevational view of the alternative embodiment of the chair assembly;

[0035] Fig. 28 is a first side elevational view of the alternative embodiment of the chair assembly;

[0036] Fig. 29 is a second side elevational view of the alternative embodiment of the chair assembly;

[0037] Fig. 30 is a rear elevational view of the alternative embodiment of the chair assembly;

[0038] Fig. 31 is a top plan view of the alternative embodiment of the chair assembly; and

[0039] Fig. 32 is a bottom plan view of the alternative embodiment of the chair assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] For purposes of description herein, the terms "upper," "lower," "right," "left,"

"rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in Figs. 1 and 2. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. [0041] The reference numeral 10 (Figs. 1 and 2) generally designates a chair assembly embodying the present invention. In the illustrated example, the chair assembly 10 includes a castered base assembly 12 abutting a supporting floor surface 13, a control or support assembly 14 supported by the castered base assembly 12, a seat assembly 16 and back assembly 18 each operably coupled with the control assembly 14, and a pair of arm assemblies 20. The control assembly 14 (Fig. 3) is operably coupled to the base assembly 12 such that the seat assembly 16, the back assembly 18 and the arm assemblies 20 may be vertically adjusted between a fully lowered position A and a fully raised position B, and pivoted about a vertical axis 21 in a direction 22. The seat assembly 16 is operably coupled to the control assembly 14 such that the seat assembly 16 is longitudinally adjustable with respect to the control assembly 14 between a fully retracted position C and a fully extended position D. The seat assembly 16 (Fig. 4) and the back assembly 18 are operably coupled with the control assembly 14 and with one another such that the back assembly 18 is movable between a fully upright position E and a fully reclined position F, and further such that the seat assembly 16 is movable between a fully upright position G and a fully reclined position H corresponding to the fully upright position E and the fully reclined position F of the back assembly 18, respectively.

[0042] The base assembly 12 includes a plurality of pedestal arms 24 radially extending and spaced about a hollow central column 26 that receives a pneumatic cylinder 28 therein. Each pedestal arm 24 is supported above the floor surface 13 by an associated caster assembly 30. Although the base assembly 12 is illustrated as including a multiple- arm pedestal assembly, it is noted that other suitable supporting structures maybe utilized, including but not limited to fixed columns, multiple leg arrangements, vehicle seat support assemblies, and the like.

[0043] The seat assembly 16 (Fig. 5) includes a relatively rigid seat support plate 32 having a forward edge 34, a rearward edge 36, and a pair of C-shaped guide rails 38 defining the side edges of the seat support plate 32 and extending between the forward edge 34 and the rearward edge 36. The seat assembly 16 further includes a flexibly resilient outer seat shell 40 having a pair of upwardly turned side portions 42 and an upwardly turned rear portion 44 that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat shell 40 is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE). In assembly, the outer seat shell 40 is secured and sandwiched between the seat support plate 32 and a plastic, flexibly resilient seat pan 46 which is secured to the seat support plate 32 by a plurality of mechanical fasteners. The seat pan 46 includes a forward edge 48, a rearward edge 50, side edges 52 extending between the forward edge 48 and the rearward edge 50, a top surface 54 and a bottom surface 56 that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan 46 includes a plurality of longitudinally extending slots 58 extending forwardly from the rea rward edge 50. The slots 58 cooperate to define a plurality of fingers 60 therebetween, each finger 60 being individually flexibly resilient. The seat pan 46 further includes a plurality of laterally oriented, elongated apertures 62 located proximate the forward edge 48. The apertures

62 cooperate to increase the overall flexibility of the seat pan 46 in the area thereof, and specifica lly allow a forward portion 64 of the seat pan 46 to flex in a vertica l direction 66 with respect to a rearward portion 68 of the seat pan 46, as discussed further below. The seat assembly 16 further includes a foam cushion member 70 that rests upon the top surface 54 of the seat pan 46 and is cradled within the outer seat shell 40, a fabric seat cover 72 (Figs. 1 and 2) and an upper surface 76 of the cushion members 70. A spring support assembly 78 (Figs. 5 and 6) is secured to the seat assembly 16 and is adapted to flexibly support the forward portion 64 of the seat pan 46 for flexure in the vertical direction 66. In the illustrated example, the spring support assembly 78 includes a support housing 80 comprising a foam and having side portions 82 defining an upwardly concave arcuate shape. The spring support assembly 78 further includes a relatively rigid attachment member 84 that extends laterally between the side portions 82 of the support housing 80 and is located between the support housing 80 and the forward portion 64 of the seat pan 46. A plurality of mechanica l fasteners 86 secure the support housing 80 and the attachment member 84 to the forward portion 64 of the seat pan 46.

The spring support assembly 78 further includes a pair of cantilever springs 88 each having a distal end 90 received through a corresponding aperture 92 of the attachment member 84, and a proximate end 94 secured to the seat support plate 32 such that the distal end 90 of each cantilever spring 88 may flex in the vertical direction 66. A pair of linear bearings 96 are fixedly attached to the attachment member 84 and aligned with the apertures 92 thereof, such that the linear bearing 96 slidably receives the distal ends

90 of a corresponding cantilever springs 88. I n operation, the cantilever springs 88 cooperate to a llow the forward portion 64 of the seat pan 46, and more generally the entire forward portion of seat assembly 16 to flex in the vertical direction 66 when a seated user rotates forward on the seat assembly 16 and exerts a downward force on the forward edge thereof.

[0044] The back assembly 18 (Figs. 7-9B) includes a back frame assembly 98 and a back support assembly 99 supported thereby. The back frame assembly 98 is generally comprised of a substantially rigid material such as metal, and includes a laterally extending top frame portion 100, a laterally extending bottom frame portion 102, and a pair of curved side frame portion 104 extending between the top frame portion 100 and the bottom frame portion 102 and cooperating therewith to define an opening 106 having a relatively large upper dimension 108 and a relatively narrow lower dimension 110.

[0045] The back assembly 18 further includes a flexibly resilient, plastic back shell 112 having an upper portion 114, a lower portion 116, a pair of side edges 118 extending between the upper portion 114 and a lower portion 116, a forwardly facing surface 120 and a rearwardly facing surface 122, wherein the width of the upper portion 114 is generally greater than the width of the lower portion 116, and the lower portion 116 is downwardly tapered to generally follow the rear elevational configuration of the frame assembly 98. A lower reinforcement member 115 attaches to hooks 117 (Fig. 9A) of lower portion 116 of back shell 112. Reinforcement member 115 includes a plurality of protrusions 113 that engage reinforcement ribs 134 to prevent side-to-side movement of lower reinforcement member 115 relative to back shell 112.

[0046] The back shell 112 also includes a plurality of integrally molded, forwardly and upwardly extending hooks 124 (Fig. 10) spaced a bout the periphery of the upper portion

114 thereof. An intermediate or lumbar portion 126 (Figs. 9A and 9B) is located vertically between the upper portion 114 a nd the lower portion 116 of the back shell 112, and includes a plurality of laterally extending slots 128 that cooperate to form a plurality of laterally extending ribs 130 located therebetween. The slots 128 cooperate to provide additional flexure to the back shell 112 in the location thereof. Pairings of lateral ribs 130 are coupled by vertically extending ribs 132 integrally formed therewith and located at a n approximate lateral midpoint thereof. The vertical ribs 132 function to tie the lateral ribs

130 together and reduce vertical spreading therebetween as the back shell 112 is flexed at the intermediate portion 126 thereof when the back assembly 18 is moved from the upright position E to the reclined position F, as described further below. The back shell 112 further includes a plurality of laterally-spaced reinforcement ribs 134 extending longitudinally along the vertical length of the back shell 112 between the lower portion 116 and the intermediate portion 126. It is noted that the depth of each of the ribs increases the further along each of the ribs 134 from the intermediate portion 126, such that the overall rigidity of the back shell 112 increases along the length of the ribs from the intermediate portion 126 toward the lower portion 116.

[0047] The back shell 112 further includes a pair of rearwardly extending, integrally molded pivot bosses 138 forming part an upper back pivot assembly 140. The back pivot assembly 140 (Figs. 11-13B) includes the pivot bosses 138 of the back shell 112, a pair of shroud members 142 that encompass respective pivot bosses 138, a race member 144, and a mechanical fastening assembly 146. Each pivot boss 138 includes a pair of side walls 148 and a rearwardly-facing concave seating surface 150 having a vertically elongated pivot slot 152 extending therethrough. Each shroud member 142 is shaped so as to closely house the corresponding pivot boss 138, and includes a plurality of side walls 154 corresponding to side walls 148, and a rearwardly-facing concave bearing surface 156 that includes a vertically elongated slot pivot slot 143 extending therethrough, and which is adapted to align with the slot 152 of a corresponding pivot boss 138. The race member 144 includes a center portion 158 extending laterally along and abutting the top frame portion 100 of the back frame assembly 98, and a pair of arcuately-shaped bearing surfaces 160 located at the ends thereof. Specifically, the center portion 158 includes a first portion 162, and a second portion 164, wherein the first portion 162 abuts a front surface of the top frame portion 100 and second portion 164 abuts a top surface of the top frame portion 100. Each bearing surface 160 includes an aperture 166 extending therethrough and which aligns with a corresponding boss member 168 integral with the back frame assembly 98.

[0048] In assembly, the shroud members 142 are positioned about the corresponding pivot bosses 138 of the back shell 112 and operably positioned between the back shell

112 a nd race member 144 such that the bearing surface 156 is sandwiched between the seating surface 150 of a corresponding pivot boss 138 and a bearing surface 160. The mechanical fastening assemblies 146 each include a bolt 172 that secures a rounded abutment surface 174 of the bearing washer 176 in sliding engagement with an inner surface 178 of the corresponding pivot boss 138, and threadably engages the corresponding boss member 168 of the back shell 112. In operation, the upper back pivot assembly 140 allows the back support assembly 99 to pivot with respect to the back frame assembly in a direction 180 (Fig. 8) about a pivot axis 182 (Fig. 7).

[0049] The back support assembly 99 (Figs. 9A and 9B) further includes a flexibly resilient comfort member 184 (Figs. 15A and 15B) attached to the back shell 112 and slidably supporting a lumbar assembly 186. The comfort member 184 includes an upper portion 188, a lower portion 190, a pair of side portions 192, a forward surface 193 and a rearward surface 195, wherein the upper portion 188, the lower portion 190 and the side portions cooperate to form an aperture 194 that receives the lumbar assembly 186 therein. As best illustrated in Figs. 9B and 14, the comfort member 184 includes a plurality of box-shaped couplers 196 spaced about the periphery of the upper portion 188 and extending rearwardly from the rearward surface 195. Each box-shaped coupler 196 includes a pair of side walls 198 and a top wall 200 that cooperate to form an interior space 202. A bar 204 extends between the side walls 198 and is spaced from the rearward surface 195. In assembly, the comfort member 184 (Figs. 12-14) is secured to the back shell 112 by aligning and vertica lly inserting the hooks 124 of the back shell 112 into the interior space 202 of each of the box-shaped couplers 196 until the hooks 124 engage a corresponding bar 204. It is noted that the forward surface 120 of the back shell 112 and the rearward surface 195 of the comfort member 184 are free from holes or apertures proximate the hooks 124 and box-shaped couplers 196, thereby providing a smooth forward surface 193 and increasing the comfort to a seated user.

[0050] The comfort member 184 (Figs. 15A and 15B) includes an integrally molded, longitudinally extending sleeve 206 extending rearwardly from the rearward surface 195 and having a rectangularly-shaped cross-sectional configuration. The lumbar assembly

186 includes a forwardly laterally concave and forwardly vertically convex, flexibly resilient body portion 208, and an integral support portion 210 extending upwardly from the body portion 208. In the illustrated example, the body portion 208 is shaped such that the body portion vertically tapers along the height thereof so as to generally follow the contours and shape of the aperture 194 of the comfort member 184. The support portion 210 is slidably received within the sleeve 206 of the comfort member 184 such that the lumba r assembly 186 is vertically adjustable with respect to the remainder of the back support assembly 99 between a fully lowered position I and a fully raised position J. A pawl member 212 selectively engages a plurality of apertures 214 spaced along the length of support portion 210, thereby releasably securing the lumbar assembly 186 at selected vertical positions between the fully lowered position I and the fully raised position J. The pawl member 212 (Figs. 16a and 16b) includes a housing portion 216 having engagement tabs 218 located at the ends thereof and rearwardly offset from an outer surface 220 of the housing portion 216. A flexibly resilient finger 222 is centrally disposed within the housing portion 216 and includes a rearward ly-extending pawl 224.

[0051] In assembly, the pawl member 212 (Fig. 17) is positioned within an aperture 226 located within the upper portion 188 of the comfort member 184 such that the outer surface 220 of the housing portion 216 of the pawl member 212 is coplanar with the forward surface 193 of the comfort member 184, and such that the engagement tabs 218 of the housing portion 216 abut the rearward surface 195 of the comfort member 184. The support portion 210 of the lumbar assembly 186 is then positioned within the sleeve 206 of the comfort member 184 such that the sleeve 206 is slidable therein and the pawl 224 is selectively engageable with the apertures 214, thereby allowing the user to optimize the position of the lumbar assembly 186 with respect to the overall back support assembly 99. Specifically, the body portion 208 of the lumbar assembly 186 includes a pair of outwardly extending integral handle portions each having a C-shaped cross-sectional configuration defining a channel 253 therein that wraps about and guides along the respective side edge 192 of the back shell 112.

[0052] In operation, a user adjusts the relative vertical position of the lumbar assembly

186 with respect to the back shell 112 by grasping one or both of the handle portions 251 and sliding the handle assembly 251 along the back shell 184 in a vertical direction. A stop tab 228 is integrally formed within a distal end 230 and is offset therefrom so as to engage an end wall of the sleeve 206 of the comfort member 184, thereby limiting the vertical downward travel of the support portion 210 of the lumbar assembly 186 with respect to the sleeve 206 of the comfort member 184.

[0053] The back assembly 99 (Figs. 9A and 9B) a lso includes a cushion member 252 having an upper portion 254 and a lower portion 256, wherein the lower portion 256 tapers along the vertical length thereof to correspond to the overall shape and taper of the back shell 112 and the comfort member 184.

[0054] The reference numeral 10a (Fig. 18) generally designates another embodiment of the chair assembly. Since the chair assembly 10a is similar to the previously described chair assembly 10, similar parts appearing in Figs. 1-17 and Figs. 18-25 respectively are represented by the same, corresponding reference numeral, except for the suffix "a" in the numerals of the latter. The chair assembly 10a is similar to the previously described chair assembly 10, with the most notable exception being the inclusion of a headrest assembly 300 and the reconfiguration of the back assembly 18a to accommodate the same. As best illustrated in Figs. 18-20, the headrest assembly is pivotable about a horizontal pivot axis 302 between a rearwardly articulated position K and a forwardly articulated position L, and vertica lly adjustable between a lowered position M and a raised position N.

[0055] In the illustrated example, the back assembly 18a includes a back frame assembly

98a and a back support assembly 99a. The back support assembly 99a is constructed in a similar manner to the back support assembly 99, as previously described. The back frame assembly includes a back frame member 304 and a back frame housing 306. The back frame member 304 includes a blade-shaped, laterally extending top frame portion 100a, a laterally extending bottom frame portion 102a, and a pair of curved side frame portions 104a extending between the top frame portion 100a and the bottom frame portion 102a and cooperating therewith to define an opening 106a. The back frame housing 306 is coupled to the back frame member 304 via a plurality of mechanical fasteners (not shown) and is configured so as to define a gap 310 therebetween that telescopingly receives the headrest assembly 300 therein.

[0056] The headrest assembly 300 includes a blade portion 314 that is telescopingly received within the gap 310 and includes a pair of elastically resilient, forwardly- extending tab members 316 that engage corresponding, rearwardly-extending ramp members 318 of the back frame housing 306, thereby securing the blade portion 314 of the headrest assembly 300 within the gap 310 and preventing removal of the headrest assembly 300 from the overall chair assembly 10a. A pair of outwardly-opening channels

320 extend along the edges of the blade portion 314 and track along corresponding track members 322 secured to the back frame member 304 during vertical adjustment of the headrest assembly 300. The blade portion 314 of the headrest assembly 300 further includes a vertically-extending, forwardly-opening channel 324 that includes a plurality of vertically-spaced detents 326 that are engaged by pawls 328 of an engagement member

330 attached to a rea r surface of the back frame housing 306. The pawls 328 selectively engage the detents 326, thereby allowing the headrest assembly 300 to be selectively vertically positioned between the lowered position M and the raised position N.

As best illustrated in Fig. 23, the headrest assembly 300 further includes a headrest frame 332 covered by a headrest cover 334 held in connection with the headrest frame 332 by a pair of stays 336 and covered by an end cover 338. In the illustrated example, the headrest frame 332 includes a laterally-extending top portion

340, a laterally-extending bottom portion 342 vertically spaced from the top portion 340, and a pair of forwardly arcuately-shaped side portions 344 horizontally spaced from one another, extending between the top portion 340 and the bottom portion 342 and cooperating therewith to define an open space 346 therebetween. The headrest cover

334 comprises an elastomeric material and is placed over the open space 346 of the headrest frame 332 such that the headrest cover 334 is stretched in the lateral direction

348. The outer lateral edges 350 (Fig. 24) of the headrest cover 334 are sewn to the stays

336 or alternatively secured by an adhesive or other suitable means. The stays 336 are positioned within outwardly-opening cha nnels 352 extending a long the side portions 344 of the headrest cover 334, and secured within the channels 352 by the elastic tension exerted by the headrest cover 334, although other alternative securing means may be utilized. An outer edge 354 (Fig. 25) of the headrest cover 334 includes a plurality of laterally-spaced apertures 356 that receive hook-shaped tabs 356 of the bottom portion

342 of the headrest frame assembly 332 therein, thereby properly aligning the headrest cover 334 with the headrest frame 332. The end cover 338 is positioned over the bottom portion 342 of the headrest frame 332, thereby concealing the outer edge 354 of the headrest cover 334. The end cover 338 is flexibly resilient and includes a plurality of tabs

360 that engage the tabs 358, thereby securing the end cover 338 to the headrest frame

332. The top portion 340 of the headrest frame 332 and the hinge cap 362 are configured similarly to the bottom portion 342 of the headrest frame 332 and the end cover 338, respectively, so as to align, secure and conceal an inner edge 364 of the headrest cover 334. A friction-locking hinge member 370 is located within the hinge cap 362 and engages the hinge cap 362 and a pair of upwardly extending arms 372 integral with the blade portion 314, thereby a llowing the headrest assembly 300 to be adjusted between the retracted position K and the extended position L.

In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without depa rting when the concept is disclosed. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.