Abstract: A load bearing fabric assembly having a frame, a carrier and a load bearing fabric. The load bearing fabric is attached directly to the carrier. The frame defines view ports to enable visual inspection of the junction between the carrier and the load bearing fabric after the carrier and fabric have been mounted to the frame. A method of manufacturing the carrier for such a load bearing fabric assembly includes the steps of: (a) placing the fabric inside a mold with at least a portion of the fabric directly engaging the surface of the mold; (b) injecting a molten thermoplastic into the mold to form the carrier, the molten thermoplastic having a melt point greater than that of the fabric; and (c) permitting the molten thermoplastic to cure to form a carrier directly on the fabric. In one embodiment, the fabric is positioned so that the entry of molten thermoplastic urges the fabric against a surface of the mold cavity.

Abstract: A load bearing surface assembly includes a molded component of oriented elastomeric material and an attachment loop connected to the molded component, the attachment loop configured to receive a frame member supporting the assembly.

Abstract: A thermoplastic spring and a method for manufacturing the thermoplastic spring are provided to reduce the effect of creep during use of the spring. The spring is molded and deformed to final dimensions by pre-inducing creep in the molded body.

Abstract: A suspended pixelated seating structure provides ergonomic, adaptable seating support. The suspended pixelated seating structure includes multiple cooperative layers to maximize global comfort and support while enhancing adaptation to localized variations in a load, such as in the load applied when a person sits in a chair. The cooperative layers each use independent elements such as pixels, springs, support rails, and other elements to provide this adaptable comfort and support. The suspended pixelated seating structure also uses aligned material to provide a flexible yet durable suspended seating structure. Accordingly, the suspended pixelated seating structure provides maximum comfort for a wide range of body shapes and sizes.

Abstract: An elastomeric load bearing surface includes an integral attachment mechanism, wherein portions of the load bearing surface attach to each other to secure the load bearing surface to a support structure. In one embodiment, a molded elastomeric strip includes a tab that wraps around a support structure frame member, and a receptacle that receives and retains the first portion. The load bearing surface may be formed from a plurality of molded elastomeric strips, each having a tab extending around the frame member and an opening receiving the tab. The strips may be oriented to reduce creep by aligning the crystalline structure of the elastomer in one direction.

Abstract: An apparatus for forming molded edges on opposite sides of a load bearing surface including a stretching assembly integrated into a molding assembly. The stretching assembly may include localized fabric clamps that leave the center region of the fabric free (e.g. not clamped) through the process. The clamps may be arranged so that once extended to stretch the fabric, the fabric is held by the clamps in the appropriate position for molding. The fabric may be held so that opposed edges terminate in the mold cavities. The mold parts may cooperatively define two spaced apart mold cavities, and may include a mold pocket to provide space to store excess fabric. The fabric may be held against the surface of the mold cavity during the molding process, for example, using hold-down pins and special gate configurations. The molding apparatus may include an alternative stretching assembly configured to provide different amounts of stretch to different portions of the fabric blank.

Abstract: A suspension seating structure having a body support assembly which includes a membrane formed from at least one strap spanning across an opening. Each strap is coupled to a frame member through a retaining structure. The retaining structure is coupled with or forms part of each frame member and provides a structurally secure body support assembly. A cushion material encapsulates the membrane, where the cushion material contains relief channels to permit the membrane to respond more freely in response to a load.

Abstract: The present invention provides a load bearing surface assembly having an oriented, molded load bearing surface intersecured with a relatively rigid orienting member. The characteristics of the orienting member are selected such that the orienting member provides a rigid edge member for holding the load bearing surface during the orienting process and/or for mounting the load bearing surface to a support structure. In one embodiment, the load bearing surface includes a pair of orienting members mounted to opposed edges of the load bearing surface. The load bearing surface may be integrally molded into a unitary construction with the orienting member(s). The present invention also provides methods for manufacturing a load bearing surface having an orienting member and a load bearing surface assembly with a load bearing surface and an orienting member.

Abstract: A suspended pixelated seating structure provides ergonomic, adaptable seating support. The suspended pixelated seating structure includes multiple cooperative layers to maximize global comfort and support while enhancing adaptation to localized variations in a load, such as in the load applied when a person sits in a chair. The cooperative layers each use independent elements such as pixels, springs, support rails, and other elements to provide this adaptable comfort and support. The suspended pixelated seating structure also uses aligned material to provide a flexible yet durable suspended seating structure. Accordingly, the suspended pixelated seating structure provides maximum comfort for a wide range of body shapes and sizes.

Abstract: An elastomeric load bearing surface includes an integral attachment mechanism, wherein portions of the load bearing surface attach to each other to secure the load bearing surface to a support structure. In one embodiment, a molded elastomeric strip includes a tab that wraps around a support structure frame member, and a receptacle that receives and retains the first portion. The load bearing surface may be formed from a plurality of molded elastomeric strips, each having a tab extending around the frame member and an opening receiving the tab. The strips may be oriented to reduce creep by aligning the crystalline structure of the elastomer in one direction.

Abstract: A suspended pixelated seating structure provides ergonomic, adaptable seating support. The suspended pixelated seating structure includes multiple cooperative layers to maximize global comfort and support while enhancing adaptation to localized variations in a load, such as in the load applied when a person sits in a chair. The cooperative layers each use independent elements such as pixels, springs, support rails, and other elements to provide this adaptable comfort and support. The suspended pixelated seating structure also uses aligned material to provide a flexible yet durable suspended seating structure. Accordingly, the suspended pixelated seating structure provides maximum comfort for a wide range of body shapes and sizes.

Abstract: A multi-layered support structure provides ergonomic, adaptable seating support. The multi-layered support structure includes multiple cooperative layers to maximize global comfort and support while enhancing adaptation to localized variations in a load, such as in the load applied when a person sits in a chair. The cooperative layers each include elements such as pixels, springs, support rails, and other elements to provide this adaptable comfort and support. The multi-layered support structure also uses aligned material to provide a flexible yet durable support structure. Accordingly, the multi-layered support structure provides maximum comfort for a wide range of body shapes and sizes.

Abstract: An attachment structure for a load bearing fabric. The attachment structure includes interfitted inner and outer rings. The outer ring includes a fabric leg 74 carrying a load bearing fabric. The inner ring defines a channel receiving the fabric leg 74. The inner ring and outer ring are configured to stretch the fabric upon insertion of the fabric leg 74 into the channel. The present invention also provides a method for securing a load bearing fabric to a support structure, generally including the steps of (a) providing an outer ring having fabric leg 74, (b) attaching a section of load bearing fabric to the fabric leg 74, (c) providing an inner ring having a channel adapted to receive the leg of the outer ring and (d) installing the outer ring to the inner ring by inserting the leg into the channel, the insertion forcing the fabric down into the channel and stretching the fabric to the desired tension.

Abstract: A suspension seating structure having a body support assembly which includes a membrane formed from at least one strap spanning across an opening. Each strap is coupled to a frame member through a retaining structure. The retaining structure is coupled with or forms part of each frame member and provides a structurally secure body support assembly. A cushion material encapsulates the membrane, where the cushion material contains relief channels to permit the membrane to respond more freely in response to a load.

Abstract: A method and apparatus for manufacturing load bearing fabric structures in which the peripheral edge of the load bearing fabric terminates with the mold cavity. The apparatus includes a stretching assembly for stretching the fabric, a fabric retaining assembly for holding the fabric in the stretched condition and a mold assembly for molding the frame about the periphery of the fabric.

Abstract: A method of packaging a molded elastomeric material includes the steps of (a) molding an elastomeric product; (b) orienting the elastomeric product by stretching or compressing the elastomeric product; (c) retaining the elastomeric product in an at least partially stretched or partially compressed configuration by mounting or securing the elastomeric product to a shunt; and (d) releasing the product from the shunt, whereby the product is capable of shrinking or expanding to its final position after it is removed from the shunt.

Abstract: A chair includes a control housing, a seat and a back support including an upwardly extending upright portion and a link portion extending forwardly from a lower portion of the upright portion. The link portion is pivotally connected to the control housing about a first pivot axis. The seat is connected to the link portion and is pivotable relative thereto. A linkage is coupled to the seat and is pivotally connected to the control housing at a second pivot axis positioned rearwardly and downwardly from the first pivot axis.

Abstract: An apparatus for attaching an item to load-bearing fabric including male and female strips that snap together on opposite sides of the fabric. The male strip is attached to the item to be secured to the fabric, and includes male prongs that are pushed through the weave of the load-bearing fabric. The female strip preferably defines a series of receptacles that snap onto the male strip. The male and female strips are elongated strips formed from a molded thermoplastic or other formable material. In a preferred embodiment, the male prongs include barbs and the receptacles include angled fingers that act as a snap, such that the barbs of the male prongs can easily be pressed through the fingers, but are retained once in place.

Abstract: An elastomeric load bearing surface with different load support characteristics in different directions. In one embodiment, the surface includes an elastomeric membrane that is oriented in only a single direction, for example, by compression or stretching. In another embodiment, the surface includes mechanical structures, such as connectors, variations in thickness and apertures, that vary the load support characteristics in different directions. In another aspect, the present invention provides a multilayer load bearing surface in which the layers cooperate to provide a controlled force/deflection profile that is variable in different regions of the surface. In one embodiment, the upper layer includes a plurality of loosely connected nodes and a lower layer having a plurality of resilient elements that separately support each node.

Abstract: An elastomeric load bearing surface with different load support characteristics in different directions. In one embodiment, the surface includes an elastomeric membrane that is oriented in only a single direction, for example, by compression or stretching. In another embodiment, the surface includes mechanical structures, such as connectors, variations in thickness and apertures, that vary the load support characteristics in different directions. In another aspect, the present invention provides a multilayer load bearing surface in which the layers cooperate to provide a controlled force/deflection profile that is variable in different regions of the surface. In one embodiment, the upper layer includes a plurality of loosely connected nodes and a lower layer having a plurality of resilient elements that separately support each node.