US Patent 11382428 Office chair seat and method of making same

An improved chair seat design is disclosed comprising a foam cushioning unit having top, middle, and bottom layers of foam secured together into a single unit. The bottom layer of foam includes a recess or slot sized to accommodate a void cell cushioning layer. The void cell cushioning layer is inserted into the recess/slot of the foam cushioning unit. Preferably, the void cell cushioning layer comprises an upper layer having an array of smaller cells with peaks pointing downwardly and pockets facing upwardly into the foam cushioning unit, and a lower layer having larger cells with peaks pointing upwardly and pockets facing downwardly relative to the foam cushioning unit. The foam cushioning unit with void cell cushioning layer inserted is then preferably attached to a contoured seat pan to form an improved office chair seat.