Pixelated support structures and elements

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.

1 . A pixelated support element for a pixelated support structure, the pixelated support element comprising: 
 a spring cradle comprising a cradle base;    a spring element at least partially disposed in the spring cradle,    where the spring cradle further comprises a spring support structure imparting a pre-selected spring stiffness to the spring element.    
   
   
       2 . The pixelated support element of  claim 1 , where the spring support structure defines a spring compression area for the spring element.  
   
   
       3 . The pixelated support structure of  claim 2 , where the spring element is an elastic spring block.  
   
   
       4 . The pixelated support structure of  claim 3 , where the elastic spring block is a gel filled spring block.  
   
   
       5 . The pixelated support element of  claim 1 , where the spring element is comprises an elastic spring arm, and where the spring support structure comprises a cradle arm extending along at least a pre-selected portion of the elastic spring arm.  
   
   
       6 . The pixelated support element of  claim 5 , where the spring element further comprises a bearing element connected to the elastic spring arm.  
   
   
       7 . A pixelated support element for a pixelated support structure, the pixelated support element 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; and    an elastomer material disposed between the upper support layer and the lower base layer,    where the first plurality of peaks is vertically aligned with the second plurality of valleys.    
   
   
       8 . The pixelated support element of  claim 7 , where the first plurality of peaks are characterized by a separation distance chosen according to a pre-selected stiffness.  
   
   
       9 . The pixelated support element of  claim 7 , where the first plurality of peaks are characterized by at least two different separation distances selected to provide at least two different pre-selected stiffnesses.  
   
   
       10 . The pixelated support element of  claim 7 , where the first plurality of peaks is characterized by a first height and the second plurality of valleys is characterized by a first depth, the first height and the first depth providing a pre-selected travel distance for the pixelated support element.  
   
   
       11 . A pixelated support element for a pixelated support structure, the pixelated support element comprising: 
 an upper bearing element;    a lower base element;    a compression spring between the upper and lower support elements; and    an elastomeric spring disposed below the compression spring.    
   
   
       12 . The pixelated support element of  claim 11 , where the elastomeric spring is retained co-axially with the compression spring.  
   
   
       13 . The pixelated support element of  claim 11 , where: 
 the upper bearing element comprises a pixelated upper bearing element array;    the lower base element comprises a pixelated lower base element array;    the compression spring is one of a plurality of compression springs between the pixelated upper bearing element array and the pixelated lower support element array; and    the elastomeric spring is one of a plurality of elastomeric springs, each disposed below a corresponding compression spring.    
   
   
       14 . The pixelated support element of  claim 13 , where the pixelated upper support array comprises a 2×2 pixelated upper support array.  
   
   
       15 . A pixelated support structure comprising: 
 a support spine;    a first spline disposed laterally across the support spine;    a first cantilever branch extending outwardly from the first spline, the first cantilever branch comprising: 
 a first terminal end connected to a spline;  
 a first support end opposite the first terminal end; and  
 a first bearing element connected to the first support end;  
   a second cantilever branch extending outwardly from the first spline adjacent to the first cantilever branch, the second cantilever branch comprising: 
 a second terminal end connected to a spline;  
 a second support end opposite the second terminal end; and  
 a second bearing element connected to the second support end; and  
   a bridging connection between the first bearing element and the second bearing element.    
   
   
       16 . The pixelated support structure of  claim 15 , further comprising: 
 a third cantilever branch extending outwardly from the first spline adjacent to the first cantilever branch, the third cantilever branch comprising: 
 a third terminal end connected to a spline;  
 a third support end opposite the third terminal end; and  
 a third bearing element connected to the third support end;  
   a fourth cantilever branch extending outwardly from the first spline adjacent to the second cantilever branch, the fourth cantilever branch comprising: 
 a fourth terminal end connected to a spline;  
 a fourth support end opposite the fourth terminal end; and  
 a fourth bearing element connected to the fourth support end; and  
   where the bridging connection connects the first, second, third, and fourth bearing elements together at a junction point to form a four-by-four pixelated group.    
   
   
       17 . The pixelated support structure of  claim 16 , further comprising: 
 a plurality of additional cantilever branches extending outwardly from the spline, each comprising an additional bearing element;    additional bridging connections forming additional four-by-four pixelated groups in a linear array laterally across the spline.    
   
   
       18 . The pixelated support structure of  claim 15 , further comprising: 
 a second spline disposed laterally across the support spine;    a third cantilever branch extending outwardly from the second spline adjacent to the first cantilever branch, the third cantilever branch comprising: 
 a third terminal end connected to a spline;  
 a third support end opposite the spline end; and  
 a third bearing element connected to the third support end;  
   a fourth cantilever branch extending outwardly from the first spline adjacent to the second cantilever branch, the fourth cantilever branch comprising: 
 a fourth terminal end connected to a spline;  
 a fourth support end opposite the spline end; and  
 a fourth bearing element connected to the fourth support end; and  
   where the bridging connection connects the first, second, third, and fourth bearing elements together at a junction point to form a four-by-four pixelated group.    
   
   
       19 . The pixelated support structure of  claim 16 , further comprising: 
 an additional spline disposed laterally across the support spine, the additional spline comprising cantilever branches extending outwardly from the spline, each comprising an additional bearing element;    additional bridging connections forming additional four-by-four pixelated groups in a linear array laterally along to the spine.    
   
   
       20 . The pixelated support structure of  claim 15 , where the spine is curved in accordance with a selected anatomical structure.  
   
   
       21 . The pixelated support structure of  claim 15 , where the spine is a back rest curved spine.  
   
   
       22 . The pixelated support structure of  claim 15 , where the spine is a seat rest curved spine.  
   
   
       23 . The pixelated support structure of  claim 16 , where the cantilever branches are characterized by a first spring rate for a pre-selected bearing element and a second spring rate for a different pre-selected bearing element.  
   
   
       24 . The pixelated support structure of  claim 17 , where the cantilever branches are characterized by a first spring rate for a pre-selected bearing element and a second spring rate for a different pre-selected bearing element.  
   
   
       25 . The pixelated support structure of  claim 18 , where the cantilever branches are characterized by a first spring rate for a pre-selected bearing element and a second spring rate for a different pre-selected bearing element.  
   
   
       26 . The pixelated support structure of  claim 19 , where the cantilever branches are characterized by a first spring rate for a pre-selected bearing element and a second spring rate for a different pre-selected bearing element.  
   
   
       27 . A pixelated support structure comprising: 
 a support spine;    a first spline perpendicularly disposed across the support spine;    a first plurality of pixelated support elements connected to the first spline in a first longitudinal array across the first spline.    
   
   
       28 . The pixelated support structure of  claim 27 , further comprising: 
 a second spline perpendicularly disposed across the support spine, and displaced along the spine from the first spline;    a second plurality of pixelated support elements connected to the second spline in a longitudinal array across the first spline.    
   
   
       29 . The pixelated support structure of  claim 27 , where the support spine is curved in accordance with a selected anatomical structure.  
   
   
       30 . The pixelated support structure of  claim 29 , where the spine is a back rest curved spine.  
   
   
       31 . The pixelated support structure of  claim 29 , where the spine is a seat rest curved spine.  
   
   
       32 . The pixelated support structure of  claim 27 , where at least one of the pixelated support elements comprises: 
 a spline connection;    a spring arm connected to the spline connection; and    a bearing element connected to the spring arm.    
   
   
       33 . The pixelated support structure of  claim 27 , where at least one of the pixelated support elements comprises: 
 a spline connection;    a first spring arm connected to the spline connection;    a first bearing element connected to the first spring arm;    a second spring arm connected to the spline connection; and    a second bearing element connected to the second spring arm.    
   
   
       34 . The pixelated support structure of  claim 32 , where the spring arm is an undulating spring arm.  
   
   
       35 . The pixelated support structure of  claim 27 , where at least one of the pixelated support elements comprises: 
 a spring cradle connected to the first spline;    a spring element at least partially disposed in the spring cradle,    where the spring cradle comprises a spring support structure imparting a pre-selected spring stiffness to the spring element.    
   
   
       36 . The pixelated support structure of  claim 35 , where the spring element comprises an elastic spring block.  
   
   
       37 . The pixelated support structure of  claim 35 , where the spring element comprises a spring arm and a bearing element connected to the spring arm.  
   
   
       38 . A pixelated support element comprising: 
 a base connection;    a first undulating compression arm connected to the base connection;    a first bearing element connected to the first undulating compression arm;    a second undulating compression arm connected to the base connection;    a second bearing element connected to the first undulating compression arm, and separated from the first bearing element.    
   
   
       39 . The pixelated support element of  claim 38 , where the base connection comprises a spline connection.  
   
   
       40 . The pixelated support element of  claim 39 , where the base connection comprises a round spline connection.  
   
   
       41 . The pixelated support element of  claim 38 , where the base connection, first and second compression arms, and first and second bearing elements comprise a single molded piece.  
   
   
       42 . A pixelated support structure comprising: 
 a backing structure ergonomically curved in accordance with a pre-selected body part;    a plurality of pixelated support elements connected to the backing structure.    
   
   
       43 . The pixelated support structure of  claim 42 , where the backing structure is a backrest.  
   
   
       44 . The pixelated support structure of  claim 43 , where the pre-selected body part is the lower back.  
   
   
       45 . The pixelated support structure of  claim 42 , where the backing structure is a seat rest.  
   
   
       46 . The pixelated support structure of  claim 45 , where the pre-selected body part includes the buttocks.  
   
   
       47 . The pixelated support structure of  claim 42 , where the plurality of pixelated support elements extend along one dimension.  
   
   
       48 . The pixelated support structure of  claim 42 , where the plurality of pixelated support elements extend along two dimensions.  
   
   
       49 . The pixelated support structure of  claim 43 , where the plurality of pixelated support elements extend along one dimension.  
   
   
       50 . The pixelated support structure of  claim 49 , where the plurality of pixelated support elements includes a first pixelated support element and a second pixelated support element, and where the first pixelated support element has a different stiffness than the second pixelated support element.  
   
   
       51 . The pixelated support structure of  claim 43 , where the plurality of pixelated support elements extend along two dimensions.  
   
   
       52 . The pixelated support structure of  claim 45 , where the plurality of pixelated support elements extend along one dimension.  
   
   
       53 . The pixelated support structure of  claim 45 , where the plurality of pixelated support elements extend along two dimensions.  
   
   
       54 . The pixelated support structure of  claim 53 , where the plurality of pixelated support elements includes a first pixelated support element and a second pixelated support element, and where the first pixelated support element has a different stiffness than the second pixelated support element.  
   
   
       55 . A pixelated support structure comprising: 
 a flexible support spine comprising an upper flexible spine section and a lower flexible spine section;    a first spline disposed laterally across the support spine; and    pixelated support elements coupled to the first spline.    
   
   
       56 . The pixelated support structure of  claim 55 , where the pixelated support elements comprise: 
 a first cantilever branch extending outwardly from the first spline, the first cantilever branch comprising: 
 a first terminal end connected to a spline;  
 a first support end opposite the first terminal end; and  
 a first bearing element connected to the first support end; and  
   a second cantilever branch extending outwardly from the first spline adjacent to the first cantilever branch, the second cantilever branch comprising: 
 a second terminal end connected to a spline;  
 a second support end opposite the second terminal end; and  
 a second bearing element connected to the second support end.  
   
   
   
       57 . The pixelated support structure of  claim 56 , further comprising a bridging connection between the first bearing element and the second bearing element.  
   
   
       58 . The pixelated support structure of  claim 55 , where the flexible support spine further comprises an inflection point between the upper support spine and the lower support spine.  
   
   
       59 . The pixelated support structure of  claim 55 , where the lower spine section flexes to support the lower back.  
   
   
       60 . The pixelated support structure of  claim 55 , where the upper spine section flexes to support the upper back.  
   
   
       61 . A pixelated support element for a pixelated support structure, the pixelated support element comprising: 
 a first undulating wire;    a second undulating wire parallel to the first undulating wire; and    a mesh attached between the first and second undulating wire.    
   
   
       62 . The pixelated support element of  claim 61 , where the mesh is a three dimensional knitted mesh.  
   
   
       63 . A pixelated support element for a pixelated support structure, the pixelated support element comprising: 
 a cylindrical mesh; and    a plurality of spring filaments woven into the cylindrical mesh.    
   
   
       64 . The pixelated support element of  claim 61 , where the mesh is a three dimensional knitted mesh.  
   
   
       65 . The pixelated support element of  claim 63 , where the spring filaments are nylon spring filaments.  
   
   
       66 . A pixelated support structure comprising: 
 a first tier comprising a connection mechanism to an underlying structural support;    a second tier coupled to the first tier;    a third tier coupled to the second tier; and    a plurality of load bearing elements coupled to the third tier.    
   
   
       67 . The pixelated support structure of  claim 66 , where the second tier is coupled to the first tier through at least one cantilever or at least one ball and socket connection.  
   
   
       68 . The pixelated support structure of  claim 66 , where the second tier is coupled to the third tier through at least one cantilever or at least one ball and socket connection.  
   
   
       69 . A multiple tier support structure comprising: 
 a first tier of load bearing elements;    load bearing element support arms coupled to the load bearing elements and to a second tier shockmount;    a second tier support arm coupled to the second tier shockmount; and    a third their support coupled to the second tier support arm.    
   
   
       70 . The multiple tier support structure of  claim 69 , where the load bearing elements comprise a first triangular load bearing element coupled through a living hinge to a second triangular load bearing element.  
   
   
       71 . A multiple tier support structure comprising: 
 a first-tier of triangular load bearing elements interconnected in hexagonal sets;    a second tier of support elements between selected load bearing elements in the first tier;    a third tier of support elements connected to selected support elements in the second tier.    
   
   
       72 . The multiple tier support structure of  claim 71 , further comprising shockmounts between the second tier and the first tier.  
   
   
       73 . The multiple tier support structure of  claim 71 , where the triangular load bearing elements are connected by bridges.  
   
   
       74 . The multiple tier support structure of  claim 73 , where the bridges are configured to permit load bearing element flexion or displacement.  
   
   
       75 . The multiple tier support structure of  claim 71 , where the second tier of support elements comprises a first connecting bar between load bearing elements in a first one of the hexagonal sets, and a second connecting bar between load bearing elements in adjacent ones of the hexagonal sets.  
   
   
       76 . The multiple tier support structure of  claim 71 , where the third tier of support elements comprises at least one conical spring.