# US 2022/0034006 A1 · System and method of manufacturing suspension member > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0034006 A1 - Document ID: US20220034006A1 - Status: Published application - Kind: A1 - Application number: 17/390,396 - Filed: 2021-07-30 - Published: 2022-02-03 - Earliest claimed: 2020-07-31 - Assignees: Herman Miller, Inc. - Applicants: Herman Miller, Inc. - Inventors: Ethan McGraw - Web page: https://patentgrep.com/patent/US20220034006A1 ## CPC - A47C 7/282: {with mesh-like supports, e.g. elastomeric membranes} - D03D 15/587: adhesive; fusible - A47C 7/32: with tensioned cords, e.g. of elastic type, in a flat plane - D03D 1/00: Woven fabrics designed to make specified articles - D03D 19/00: Gauze or leno-woven fabrics - D03D 49/16: Warp supplied by creel - D03J 1/06: for treating fabric (cutting pile on the loom D03D39/24) - D06C 7/00: Heating or cooling textile fabrics - D10B 2505/08: Upholstery, mattresses - A47C: CHAIRS; SOFAS; BEDS - D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS - D03J: AUXILIARY WEAVING APPARATUS; WEAVERS' TOOLS; SHUTTLES - D06C: FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES ## Abstract A method of manufacturing a suspension member including providing a first set of yarns and a second set of yarns, combining the first set of yarns and the second set of yarns to form the suspension member, and at least partially bonding a portion of the first set of yarns and the second set of yarns together by heating the suspension member to form a first zone of the suspension member having a first tension. ## Claims ### Claim 1 A method of manufacturing a suspension member, the method comprising: providing a first set of yarns and a second set of yarns; combining the first set of yarns and the second set of yarns to form the suspension member; and at least partially bonding a portion of the first set of yarns and the second set of yarns together by heating the suspension member to form a first zone of the suspension member having a first tension. ### Claim 2 (depends on 1) The method of claim 1, wherein bonding the portion of the first set of yarns and the second set of yarns together further forms a second zone of the suspension member having a second tension that is different from the first tension. ### Claim 3 (depends on 2) The method of claim 2, wherein bonding the portion of the first set of yarns and the second set of yarns together includes applying different amounts of heat to the first zone of the suspension member and to the second zone of the suspension member. ### Claim 4 (depends on 1) The method of claim 1, wherein the combining the first set of yarns and the second set of yarns includes feeding the first set of yarns and the second set of yarns through a loom and weaving the second set of yarns through the first set of yarns. ### Claim 5 (depends on 4) The method of claim 4, further comprising tensioning a portion of the first set of yarns before the combining the first set of yarns and the second set of yarns. ### Claim 6 (depends on 4) The method of claim 4, further comprising tensioning a portion of the first set of yarns during the combining the first set of yarns and the second set of yarns. ### Claim 7 (depends on 1) The method of claim 1, wherein bonding the portion of first set of yarns and the second set of yarns together includes heating the suspension member in a continuous manner. ### Claim 8 (depends on 1) The method of claim 1, wherein bonding the portion of first set of yarns and the second set of yarns together includes heating the suspension member in a discontinuous manner. ### Claim 9 (depends on 1) The method of claim 1, wherein bonding the portion of the first set of yarns and the second set of yarns together includes moving a heating element towards and away from the suspension member to control an amount of heat applied to the suspension member. ### Claim 10 (depends on 1) The method of claim 1, further comprising providing a heating element and moving the heating element towards and away from the suspension member during the bonding the portion of first set of yarns and the second set of yarns together. ### Claim 11 A bonding unit for manufacturing a suspension member, the bonding unit comprising: at least one heating element configured to heat at least a portion of the suspension member; a feed roller positioned upstream of the at least one heating element proximate an entrance of the bonding unit, the feed roller configured to move the suspension member through the bonding unit; a take-up roller positioned downstream of the at least one heating element proximate an exit of the bonding unit, the take-up roller configured to move the suspension member through the bonding unit; and a controller configured to adjust the intensity of heat emitted to the suspension member from the at least one heating element. ### Claim 12 (depends on 11) The bonding unit of claim 11, wherein the heating element is movable toward and away from the suspension member. ### Claim 13 (depends on 12) The bonding unit of claim 12, wherein the controller is configured to control a distance between the heating element and the suspension member. ### Claim 14 (depends on 11) The bonding unit of claim 11, wherein the at least one heating element includes a plurality of heating elements, and wherein some of the plurality of heating elements are positioned closer to the suspension member than others of the plurality of heating elements. ### Claim 15 (depends on 11) The bonding unit of claim 11, further comprising at least one screen configured to block heat from reaching the suspension member. ### Claim 16 (depends on 15) The bonding unit of claim 15, wherein the controller is configured to move the screen into or out of a blocking position at a desired time. ### Claim 17 A suspension member comprising: a first plurality of yarns forming a first zone having a first tension; and a second plurality of yarns forming a second zone having a second tension that is different from the first tension, wherein at least some of the first plurality of yarns in the first zone are fused together. ### Claim 18 (depends on 17) The suspension member of claim 17, wherein the at least some of the first plurality of yarns have a different melting point than at least some of the second plurality of yarns. ### Claim 19 (depends on 17) The suspension member of claim 17, wherein at least some of the second plurality of yarns in the second zone are fused together. ### Claim 20 (depends on 17) A chair comprising a frame and a carrier retaining the suspension member of claim 17, wherein the suspension member extends across the frame.