Abstract: A seating unit is provided having a base, a back frame pivoted to the base for movement between upright and reclined positions, and a seat slidably supported on the base assembly and pivoted to the back frame so that the seat moves forwardly and its rear moves forwardly and downwardly with the back frame upon recline. A flexible back shell is connected to the back frame at top and bottom locations for controlled flexure when a seated user reclines and/or flexes his/her back, and is provided with lumbar adjustment for improved lumbar force/support and shape.

Abstract: A seating unit includes a seat and back operably supported for synchronized reclining movement. The back includes a back support with separate upper and lower portions pivotally coupled to a back frame at upper and lower connections, respectively. The upper and lower portions combine to define a forwardly-protruding convex shape and include mating structure forming an expansion joint that permits collapse and expansion as the upper and lower portions are flexed between a more-convex shape and a more-planar shape. In one form, the lower portion includes first and second sections pivoted together, with the upper portion and the first and second sections forming thoracic, lumbar, and pelvic regions of the back support, respectively.

Abstract: A seating unit is provided having a base, a back frame pivoted to the base for movement between upright and reclined positions, and a seat slidably supported on the base assembly and pivoted to the back frame so that the seat moves forwardly and its rear moves forwardly and downwardly with the back frame upon recline. A flexible back shell is connected to the back frame at top and bottom locations for controlled flexure when a seated user reclines and/or flexes his/her back, and is provided with lumbar adjustment for improved lumbar force/support and shape.

Abstract: A seating unit includes a seat and back operably supported for synchronized reclining movement. The back includes a back support with separate upper and lower portions pivotally coupled to a back frame at upper and lower connections, respectively. The upper and lower portions combine to define a forwardly-protruding convex shape and include mating structure forming an expansion joint that permits collapse and expansion as the upper and lower portions are flexed between a more-convex shape and a more-planar shape. In one form, the lower portion includes first and second sections pivoted together, with the upper portion and the first and second sections forming thoracic, lumbar, and pelvic regions of the back support, respectively.

Abstract: A back construction for a seating unit includes a back frame, and a compliant back having a forwardly-protruding lumbar support section that is characteristically flexible and bendable, such that the compliant back can be flexed to a plurality of different convex shapes. Top and bottom connections pivotally connect the compliant back to the back frame. An adjustable force-generating mechanism is operably attached to at least one of the compliant back and the back frame. The force-generating mechanism is constructed to provide an adjustable biasing force that adjustably biases the lumbar support section forwardly for optimal lumbar support for a seated user's back, but the force-generating mechanism characteristically provides the biasing force without forcing a shape change in the compliant back. A vertically adjustable lumbar support is slidably attached to the back shell.

Abstract: A back for a seating unit, such as a chair, includes a back frame and a compliant back that is flexibly bendable to define different curvilinear shapes for sympathetically and ergonomically supporting a seated user's back. The back includes a bracket with forwardly-extending flanges pivotally connecting the compliant back to the back frame at a bottom connection generally aligned with a seated user's hip joint. The back also includes a top connection pivotally connecting the back to the back frame above the first connection. An adjustable torsional force-generating mechanism is connected to the first connection that biases a lumbar portion of the compliant back forward with respect to the chair. The top and bottom connections, in combination with the adjustable force generating mechanism, constrain the compliant back to move over a range that provides excellent ergonomic lumbar support to a seated user.

Abstract: A seating unit includes a flexible back including a concavely-shaped lumbar region, and a tensioned cover stretched over the concavely-shaped lumbar region. A lumbar device is fit between the front surface and the covering, with a tension of the covering biasing the lumbar device against the lumbar region and resulting in a frictional force retaining the lumbar device in a selected vertical position. In one form, the lumbar device is sufficiently stiff to maintain its vertical cross sectional shape and to change a shape of the lumbar region as the lumbar device is adjusted vertically, but is sufficiently flexible to conform to a horizontal shape of the lumbar region as a seated user moves and twists while seated in the seating unit.

Abstract: A back for a seating unit, such as a chair, includes a back frame and a compliant back that is flexibly bendable to define different curvilinear shapes for sympathetically and ergonomically supporting a seated user's back. The back includes a belt bracket with forwardly-extending flanges pivotally connecting the back to the back frame at a first connection generally aligned with a seated user's hip joint. The back includes a second connection pivotally connecting the back to the back frame at a second location spaced vertically above the first connection. An adjustable force generating mechanism is connected to the first connection that biases a lumbar portion of the back forward with respect to the chair. The first and second connections, in combination with the adjustable force generating mechanism, constrain the compliant back to move over a range that provides excellent ergonomic lumbar support to a seated user.

Abstract: A seating unit is provided having a base assembly, a back frame pivoted to the base assembly for movement between upright and reclined positions, and a seat slidably supported on the base assembly and pivoted to the back frame so that the seat moves forwardly and its rear moves forwardly and downwardly with the back frame upon recline. A flexible back is connected to the back frame at top and bottom locations and is provided with lumbar adjustment for improved lumbar force/support and shape. A seat is provided with seat depth adjustment and with active and passive thigh flex support. A novel energy mechanism is provided that includes a moment arm shift adjuster for adjusting the spring tension on the back frame. The moment arm shift adjuster is readily adjustable and includes an overtorque device to prevent damage to components of the energy mechanism.

Abstract: A back construction for a seating unit includes a back frame, and a compliant back having a forwardly-protruding lumbar support section that is characteristically flexible and bendable, such that the compliant back can be flexed to a plurality of different convex shapes. Top and bottom connections pivotally connect the compliant back to the back frame. An adjustable force-generating mechanism is operably attached to at least one of the compliant back and the back frame. The force-generating mechanism is constructed to provide an adjustable biasing force that adjustably biases the lumbar support section forwardly for optimal lumbar support for a seated user's back, but the force-generating mechanism characteristically provides the biasing force without forcing a shape change in the compliant back. A vertically adjustable lumbar support is slidably attached to the back shell.

Abstract: A back for a seating unit, such as a chair, includes a back frame and a compliant back that is flexibly bendable to define different curvilinear shapes for sympathetically and ergonomically supporting a seated user's back. The back includes a bracket with forwardly-extending flanges pivotally connecting the compliant back to the back frame at a bottom connection generally aligned with a seated user's hip joint. The back also includes a top connection pivotally connecting the back to the back frame above the first connection. An adjustable torsional force-generating mechanism is connected to the first connection that biases a lumbar portion of the compliant back forward with respect to the chair. The top and bottom connections, in combination with the adjustable force generating mechanism, constrain the compliant back to move over a range that provides excellent ergonomic lumbar support to a seated user.

Abstract: A chair is provided having a base assembly, a back assembly pivoted to the base assembly for movement between upright and reclined positions, and a seat slidably supported on the base assembly and pivoted to the back frame so that the seat moves forwardly and its rear moves forwardly and downwardly with the back frame upon recline. A flexible back is connected to the back frame at top and bottom locations and is provided with lumbar adjustment for improved lumbar force/support and shape. A seat is provided with seat depth adjustment and with active and passive thigh flex support. A novel energy mechanism is provided that includes a moment arm shift adjuster for adjusting the spring tension on the back frame. The moment arm shift adjuster is readily adjustable and includes an overtorque device to prevent damage to components of the energy mechanism.

Abstract: A method for making upholstered articles comprising a foam core, an integrally attached cover assembly, and an integrally attached scrim is provided. The method includes the step of positioning an air-impermeable cover assembly over a mold cavity of a molding apparatus, applying a vacuum to the fabric through a plurality of apertures in the walls defining the mold cavity to cause the fabric to conform to the shape of the mold cavity, depositing a foam precursor into the mold cavity, positioning an air-impermeable scrim over the foam, and allowing the foam precursor to expand to form the article. The method allows upholstered articles having an integrally attached cover assembly to be manufactured using a pour-in-place process which does not utilize abherents, while still preventing bonding of the foam core to the lid and/or other surfaces of the molding apparatus.