Patent Grant
10085564
Aspects of this disclosure relate generally to upholstery furniture. More particularly, this disclosure includes aspects relating to an adjustable lumbar support for use in motion upholstery furniture.
Certain current lumbar support systems utilized in various chairs, seats, or other furniture can provide lumbar support mechanically or with an air bladder. However, such current lumbar support systems are not strong enough to provide adequate lumbar support that can be felt by an occupant through thick padding often found on a variety of upholstered furniture. Further, some current lumbar support systems only provide lumbar support across a small portion of a lower region of a seat back, which can lead to occupant discomfort. What is needed is a lumbar support mechanism for use on upholstered furniture that can provide enhanced lumbar support across a substantial portion of a lower or lumbar region of a seat back.
The present disclosure generally relates to an adjustable lumbar support mechanism for upholstered furniture. The lumbar support mechanism can include a lumbar support member coupled, via at least one lumbar support link, to an actuating mechanism. Upon extension of an extendable shaft associated with the actuating mechanism, the lumbar support member can shift from a retracted position to an extended position, where the lumbar support member is at least partly positioned more towards the seat in order to provide lumbar support for an occupant.
Accordingly, in one aspect, an adjustable lumbar support mechanism is provided. The adjustable lumbar support mechanism can provide lumbar support in a seating unit having a seat and a seat back having a back frame, the back frame having opposing first and second side frame members, and opposing top and bottom frame members, the bottom frame member being positioned adjacent the seat. The adjustable lumbar support mechanism includes a lumbar support member, the lumbar support member having opposing first and second ends; and at least one lumbar support link fixedly coupled to one of the first and second ends of the lumbar support member. The adjustable lumbar support mechanism also includes at least one lumbar mounting plate pivotably coupled to the at least one lumbar support link at a mounting plate pivot point, and one or more actuating mechanisms. Each of the one or more actuating mechanisms includes an extendable shaft pivotably coupled to the at least one lumbar support link at an extendable shaft pivot point, where when the extendable shaft is shifted from a retracted position to an extended position, the at least one lumbar support link is configured to rotate relative to the at least one lumbar mounting plate thereby positioning at least a portion of the lumbar support member away from the back frame and towards the seat.
In another aspect, a residential furniture seating unit is provided. The residential furniture seating unit includes a seat spaced above a surface on which the seating unit rests, and a seat back extending upwardly from the seat adjacent a rear portion of the seat. The seat back includes a seat back frame having opposing first and second side frame members, and opposing top and bottom frame members, the bottom frame member being positioned adjacent the seat. The residential furniture seating unit also includes an adjustable lumbar support mechanism. The adjustable lumbar support mechanism includes a lumbar support member, the lumbar support member having opposing first and second ends; and at least one lumbar support link fixedly coupled to one of the first and second ends of the lumbar support member. The adjustable lumbar support mechanism also includes at least one lumbar mounting plate pivotably coupled to the at least one lumbar support link at a mounting plate pivot point; and one or more actuating mechanisms. Each of the one or more actuating mechanisms comprises an extendable shaft pivotably coupled to the at least one lumbar support link at an extendable shaft pivot point, where when the extendable shaft is shifted from a retracted position to an extended position, the at least one lumbar support link is configured to rotate relative to the at least one lumbar mounting plate thereby positioning at least a portion of the lumbar support member away from the seat back frame and towards the seat.
The accompanying drawings form a part of the specification, are to be read in conjunction therewith, and are incorporated by reference in their entirety. In the drawings:
The subject matter of aspects of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventor has contemplated that the claimed subject matter might also be embodied in other ways, to include different elements or combinations of elements similar to the ones described in this document, in conjunction with other present or future technologies.
Throughout this disclosure various components are described that are pivotably interconnected. The pivotable couplings (illustrated as pivot points in the figures and described herein) between these components can take a variety of configurations, such as pivot pins, bearings, traditional mounting hardware, rivets, bolt and nut combinations, or any other suitable fasteners which are well known in the furniture-manufacturing industry. Also, the shapes of the links and the brackets may vary as desired, as may the locations of certain pivot points, unless otherwise indicated.
As discussed above, the present invention relates broadly to upholstery furniture designed to support a user's body in an essentially seated disposition. One category of this furniture is motion upholstery furniture, including recliners, incliners, sofas, love seats, sectionals, theater seating, traditional chairs, and chairs with a moveable seat portion, such furniture pieces being referred to herein generally as “seating units.”
An exemplary seating unit 100 is shown in
Turning now to
In certain aspects, such as that depicted in
In certain aspects, the adjustable lumbar support mechanism is designed to provide an economical lumbar support mechanism 300 that can be utilized in a wide variety of motion upholstery furniture. In such aspects, the adjustable lumbar support mechanism 300 can include minimal components in order to keep manufacturing costs down and to provide a compact support mechanism that can be utilized in a wide variety of motion upholstery furniture. Accordingly, in one or more aspects, the adjustable lumbar support mechanism 300 comprises, consists essentially of, or consists of a lumbar support member 310, one or more lumbar support links 320, an actuating mechanism 330, an actuator mounting plate 340, and one or more lumbar support member mounting plates 350.
In certain aspects, the lumbar support member 310 can include opposing ends 312 and 314. In one or more aspects, the end 312 of the lumbar support member 310 can be coupled, e.g., fixedly coupled, to the lumbar support link 320. In various aspects, the lumbar support link 320 and the end 312 of the lumbar support member 310 can be fixedly coupled using any conventional techniques, such as by the use of rivets, bolts, screws, or welding.
In one or more aspects, the lumbar support link 320 can be coupled, e.g., pivotably coupled, to the lumbar support member mounting plate 350 at a mounting plate pivot point 322. In certain aspects, the lumbar support member mounting plate 350 may be fixedly coupled to a portion of the side frame member 406 via one or more connectors 352. As best seen in
As discussed above, the lumbar support mechanism 300 can include an actuating mechanism 330. The actuating mechanism 330 can be any type of actuating mechanism commonly used in the furniture-manufacturing industry. In one aspect, the actuating mechanism 330 can include an extendable shaft 332. The extendable shaft 322 can be coupled, e.g., pivotably coupled, to the lumbar support link 320 at an extendable shaft pivot point 324. In certain aspects, the extendable shaft pivot point 324 can be positioned adjacent the end 326 of the extendable shaft 332. In one or more aspects, the end 326 of the extendable shaft 322 can include a clevis 327 that can be used for pivotably coupling the lumbar support link 320 the extendable shaft 332.
In various aspects, the extendable shaft 332 and the extendable shaft pivot point 324 can be positioned closer to the back portion 409 than the front portion 407 of the frame member 406. In the same or alternative aspects, the extendable shaft pivot point 324 can be positioned closer to the back portion 409 of the frame member 406 than the mounting plate pivot point 322, and/or the mounting plate pivot point 322 can be positioned closer to the front portion 407 of the frame member 406 than the extendable shaft pivot point 324. In certain aspects, this positioning of the extendable shaft 332, the extendable shaft pivot point 324, the lumbar support member 310, and/or the mounting plate pivot point 322 can maximize the force generated by the extension of the extendable shaft 332 in order to provide adequate force to move the lumbar support member 310 forward towards the seat 110 and up against any upholstery and/or padding on the back 120 of the seating unit 100 to provide lumbar support to a chair occupant.
In certain embodiments, the actuating mechanism 330 can be coupled to the frame 400 of the seating unit 100 via an actuator mounting plate 340. The actuator mounting plate 340 can be fixedly coupled to the frame member 406 via one or more connectors 342. The actuating mechanism 330 can be coupled to the actuator mounting plate 340 in any manner. In certain aspects, the actuating mechanism 330 can include a clevis 334 for coupling to the actuator mounting plate 340. In such aspects, the clevis 334 can allow for at least a portion of the actuating mechanism 330 to pivot relative to the actuator mounting plate 340 at an actuator pivot point 335.
While not shown in the figures, the actuating mechanism 330 may be coupled to an activator, such as a remote control or a switch, for use by the chair occupant. Such an activator can control the retraction and extension of the extendable shaft 332 of the actuating mechanism to a position desired by the chair occupant.
As can be seen in
Turning now to
As can be seen in
In certain aspects, the final mounting position of the lumbar support member 310 may be modified to provide a retracted configuration where the position of the lumbar support member 310 is chosen for a particular feel in any given application. For example, in an aspect not depicted in the figures, a lumbar support member, such as lumbar support member 310, may protrude past the front portion 407 of the side frame member 406 so that, in the retracted configuration, the lumbar support member 310 provides a little amount of lumbar support to a chair occupant. In such aspects, when in the retracted configuration, the lumbar support member 310 may extend at least about 0.5 inches, at least about 0.75 inches, at least about 1 inch, or at least about 1.5 inches past the front portion 407 of the side frame member 406.
As can be seen in
As mentioned above, in certain aspects, the position of the lumbar support member 310, the extendable shaft pivot point 324, and/or the mounting plate pivot point 322 are configured to transfer the downward force that can be supplied by the extendable shaft 332 into an adequate force that can move the exterior surface 316 of the lumbar support member 310 up against any upholstery or padding in the back 120 in order to provide lumbar support to a chair occupant. For example, as the extendable shaft 332 extends, a downward force is applied to the extendable shaft pivot point 324 and/or to the mounting plate pivot point 322, which can cause the lumbar support link 320 to pivot or rotate about the extendable shaft pivot point 324 and/or the mounting plate pivot point 322. Further, in such aspects, this pivoting motion of the lumbar support link 320 can cause the lumbar support member 310 and its exterior surface 316 to rotate out and away from the back portion 409 of the side frame member 406 and towards the seat 110.
In one or more aspects, when the extendable shaft 332 is shifting between the retracted configuration and the extended configuration, or from the extended configuration to the retracted configuration, the actuating mechanism 330 may shift laterally towards the back portion 409 or the front portion 407 of the side frame member 406, e.g., by moving about the actuator pivot point 335 and/or the extendable shaft pivot point 324. In such aspects, a lateral movement of the actuating mechanism 330 towards the back portion 409 of the side frame member 406 may provide additional leverage and power to the lumbar support member 310 as it shifts out and away from the back portion 409 of the side frame member 406 and towards the seat 110. Further, in such aspects, a minor lateral shifting of the actuating mechanism 330 may transfer some of the force received by the actuating mechanism 330 during extension or retraction, which may decrease wear of the actuating mechanism 330.
The length ll of the lumbar support member 310, defined as the length between the sides 312 and 314, can be any length chosen by one skilled in the art for a particular purpose. In certain aspects, the lumbar support member 310 may extend along a substantial portion of the width of the back 120, which may be advantageous for providing lumbar support across a substantial portion of the back 120. For example, as best seen in
As discussed above, when the adjustable lumbar support mechanism 300 is in an extended configuration the external surface 316 of the lumbar support member 310 may contact the upholstery and/or padding and provide lumbar support to a chair occupant. Thus in certain aspects, the shape of the external surface 316 may affect the lumbar support experience by a chair occupant. In one or more aspects, the exterior surface 316 can be curved. In various aspects, a curved exterior surface 316 can provide more directed or pointed lumbar support for a chair occupant, as the curve may be convex. In such aspects, a curved exterior surface 316 having a convex shape in combination with the adjustable extension (and thus position) of the lumbar support member 310, allows for a fully adjustable and customizable lumbar support experience for a chair occupant.
As best seen in
In certain aspects, the distinct arcs 504 and 506 can have varying heights, h1 and h2, respectively. The heights are defined as the maximum height h1 and h2 of the arcs 504 and 506, respectively, as measured relative to the base 501 of the lumbar support member 500. In such aspects, as these arcs 504 and 506 are distinct from one another, it follows that these arcs would have distinct radii of curvature to at least partly define these arcs 504 and 506. It should be understood that the exterior surface 502 can include more than two distinct arcs.
In one or more aspects, the lumbar support member can include a complex curved surface that includes more than one arc where the arcs are blended together to provide a smoother exterior surface. For example as depicted in
In various aspects, by utilizing a lumbar support mechanism with a lumbar support member having an exterior surface with a compound curve, such as the lumbar support member exterior surfaces 502 and 606 depicted in
Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Aspects of our technology have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations and are contemplated within the scope of the claims.
It will be seen from the foregoing that this invention is one well adapted to attain the ends and objects set forth above, and to attain other advantages, which are obvious and inherent in the device. It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. Rather, all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not limiting.
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