TECHNICAL FIELD
Embodiments of the present invention relate to an ottoman linkage for use on a chair with a high-leg design, and to recliner seating mechanisms and chairs using them, and particularly to a powered recliner seating mechanism with an ottoman linkage and motor that are hidden from view when in a stored position.
BACKGROUND OF THE INVENTION
One design of chairs using a reclining mechanism is known as a high-leg design. In these types of chairs, the legs suspend the seat above a flooring surface such that one can see under the chair. In a chair having a powered ottoman linkage mechanism and/or a reclining mechanism, and a high-leg styling, it is desirable to provide a mechanism and motor that can be completely hidden from sight, without altering the overall design of the chair.
BRIEF DESCRIPTION OF THE INVENTION
A seating unit is provided that is moveable between closed, extended and fully reclined positions. The seating unit comprises two sides spaced from one another, each side having a lower edge and an upper edge, a seat extending between the two sides, a six bar linkage driving an extendable ottoman and a chair back extending upwardly from a rearward edge of the seat. The seating unit further comprises a pair of side plates, each side plate coupled to a corresponding one of the two sides; a linkage mechanism supported between the side plates and coupling at least the seat, the ottoman, and the chair back, the linkage mechanism having a height in the closed position and a lowest-most extent, wherein the lowest most extent is above the lower edge of the sides; and a motor coupled to the linkage mechanism to move the seating unit between the closed, extended and fully reclined positions.
In other aspects, an ottoman linkage is provided that is movable between a closed, stowed position and an extended position, without also moving the seat or back, but while still providing an extendable ottoman while still allowing a high-leg styling.
Additional objects, advantages, and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
The present invention is described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a side view of a prior art high leg chair, in which a portion of the linkage mechanism is exposed in the closed position;
FIG. 2 is a side view of a seating unit in accordance with an embodiment of the invention;
FIG. 3 is a view similar to FIG. 2, but showing the opposite side, and without the side frame and seat upholstery;
FIG. 4 is a perspective view of the linkage mechanism of seating unit of FIGS. 2 and 3;
FIG. 5 is a side view of the mechanism of FIG. 4;
FIG. 6 is a view similar to FIG. 5, shown without the arm plate;
FIG. 7 is a top view of the seating unit, showing a seat frame;
FIG. 8 is a perspective view similar to FIG. 4, but with the mechanism in the TV position;
FIG. 8A is an enlarged view of the encircled region 8A in FIG. 8;
FIG. 9 is a side view of the linkage mechanism in the TV position;
FIG. 10 is a view similar to FIG. 9, but shown without the arm plate;
FIG. 11 is a side view of the seating unit in the TV position;
FIG. 12 is a perspective view similar to FIG. 8, but with the mechanism in the fully reclined position;
FIG. 13 a side view of the linkage mechanism in the fully reclined position;
FIG. 14 is a view similar to FIG. 13, but shown without the arm plate;
FIG. 15 is a side view of the seating unit in the fully reclined position;
FIG. 16 is a perspective view of an alternative aspect of a mechanism for use on a chair where the ottoman is extendable, but the seat and back remain stationary;
FIG. 17 is an inside elevation view of the mechanism of FIG. 16;
FIG. 18 is an outside elevation view of the mechanism of FIG. 16;
FIG. 19 is a view similar to FIG. 16, but shown with the ottoman linkage extended;
FIG. 20 is an inside elevation view of the mechanism of FIG. 19;
FIG. 21 is an outside elevation view of the mechanism of FIG. 19;
FIG. 22 is a view of the mechanism of FIG. 16, shown within the context of a partial seat frame;
FIG. 23 is a side view of a seating unit in accordance with an alternative aspect of the invention;
FIG. 24 is a view similar to FIG. 23, but showing the opposite side, and without the side frame and seat upholstery;
FIG. 24A is an enlarged view of certain portions of the seating unit of FIG. 24, with some parts hidden to reveal details of construction;
FIG. 25 is a perspective view of the linkage mechanism of seating unit of FIGS. 23 and 24;
FIG. 26 is a side view of the mechanism of FIG. 25;
FIG. 27 is a view similar to FIG. 26, shown without the arm plate;
FIG. 28 is a top view of the seating unit, showing a seat frame;
FIG. 29 is a perspective view similar to FIG. 25, but with the mechanism in the TV position;
FIG. 30 is an enlarged view of the of the front portion of the mechanism in FIG. 29;
FIG. 31 is a side view of the linkage mechanism in the TV position;
FIG. 32 is a view similar to FIG. 30, but shown without the arm plate;
FIG. 33 is a side view of the seating unit in the TV position;
FIG. 34 is a perspective view similar to FIG. 29, but with the mechanism in the fully reclined position;
FIG. 35 a side view of the linkage mechanism in the fully reclined position;
FIG. 36 is a view similar to FIG. 35, but shown without the arm plate; and
FIG. 37 is a side view of the seating unit in the fully reclined position.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention generally relate to a seating unit having a motorized mechanism, usable on a high-leg styled chair, that is hidden from view and that moves the ottoman from a closed position to an extended position, and can recline the back of the seating unit with the ottoman extended.
As shown in FIG. 1, a prior art high-leg chair 10 may have legs 12 that support the sides 14 above a support surface (such as a floor). The chair 10 may include a mechanism 16 that allows the chair 10 to move from a closed position to an extended position and to a fully-reclined position. As shown in FIG. 1, certain portions of the mechanism 16 may be exposed and visible in the closed position (such as portions of links, portions of support tubes, or portions of the motor), which is undesirable. The chair designer and manufacturer is left with the option of leaving those certain portions of the mechanism 16 visible, or changing the style and shape of the chair sides to obscure those portions of the mechanism. It would be desirable to provide a mechanism that does not require the chair designer and manufacturer to choose between these two options.
A seating unit 20 is shown in FIG. 2 in a closed position. The seating unit 20, in some aspects, has legs 22 that support the remainder of the seating unit 20 above the floor or other support surface. The seating unit 20 may also include a side frame 24 that supports a linkage mechanism 26 (shown in more detail in other figures). The seating unit 20, in some aspects, may also have arms (not shown). The mechanism 26 is coupled to a seat frame 28 that supports a seat 30, a back frame 32 (which supports upholstery which is not shown) and an ottoman 34 (see FIG. 3, which is discussed further below). The mechanism 26 allows the seating unit 20 to use what is known as “high-leg” styling with a very compact mechanism height that allows the side frame 24 to obscure mechanism 26 from view, and that allows the chair to be placed close to an adjacent wall (a wall-proximity chair). As seen in FIG. 2, the legs 22 support the seating unit above the floor at a leg height (LH) measured from the floor to the lower edge of the side frame 24. In some aspects, the leg height is between seven and eight inches. In some aspects, the seat 30 is positioned above the floor at a seat height (SH) that may be about 20 inches. The space between the lower edge of the side frame 24 and the lower edge of the seat frame 28 is occupied by the mechanism 26. Because the seat frame 28 typically sits at an angle, the space available for the mechanism height (MH) may be measured from different points. In some aspects, a mechanism height (MH1) may be the distance from the lower edge of the side frame 24 to a top and front edge 36 of the seat frame 28. In other aspects, a mechanism height (MH2) may be the distance from the lower edge of the side frame 24 to a point 38 (discussed further below) on a seat rail 40 that obscures the majority of the mechanism 26. With a very compact mechanism 26, designers of the seating unit 20 are able to provide a higher leg distance (LH) and a lower seat height (SH) if that is desired, while still offering a wall-proximity chair. This is made possible by the mechanism 26 with a lower mechanism height (MH) than was previously possible. For example, in some aspects, MH2 is in the range of about 140 mm to 160 mm, compared with prior mechanisms where a comparable MH2 is 170 mm or more. The mechanism 26 thus allows a three-way reclining (moving between closed, TV and fully-reclined positions), wall-proximity chair, with a seat height (SH) comparable to other chairs in the market, but with a higher leg height (LH), while offering a mechanism that is hidden from view in the closed position.
As shown in FIG. 5, the mechanism 26 includes an arm mounting plate 42 that is used to couple the mechanism 26 to the side frame 24. A rear recline linkage 44 is pivotally coupled to the arm mounting plate 42 at pivot points 46 and 48. The rear recline linkage 44 includes a control link 50 that is pivotally coupled to the arm mounting plate at pivot point 46. As seen in FIG. 6, the control link 50 (opposite pivot point 46) is pivotally coupled to a rear travel link 52 at pivot point 54. The other end of the rear travel link 52 is pivotally coupled to a trolley link 56 at pivot point 58. Generally mid-way between pivot point 54 and pivot point 58, the rear travel link 52 is pivotally coupled to a pivot control link 60 at pivot point 62. The end of the pivot control link 60 opposite pivot point 62 is pivotally coupled to the arm mounting plate at pivot point 48. As will be further discussed below, the rear recline linkage 44 (including the control link 50, the rear travel link 52 and the pivot control link 60) is located more rearwardly, and higher, than in previous mechanisms, allowing for a very compact mechanism 26.
As seen in FIG. 4, a rear motor tube 63 is coupled between opposing arm mounting plates 42. The rear motor tube 63 pivotally supports a motor 64 as more-fully described below. Additionally, a rear stabilizer tube 66 is fixedly coupled to the lower end of rear travel link 52 with a flange 68 (as seen in FIG. 4). The rear stabilizer tube 66 extends between opposing rear travel links 52.
As seen in FIGS. 4 and 5, a seat plate extension 70 is fixedly coupled to the seat rail 40. The combination of the seat rail 40 and the seat plate extension 70 may be referred to as a seat plate. The seat plate extension 70 generally extends rearwardly and upwardly from the seat rail 40. A back bracket 72 is pivotally coupled to the seat plate extension 70 at pivot point 74. The back bracket 72 is used to support the back frame 32 of the seating unit 20, and the back frame 32 moves in connection with the movement of the back bracket 72. Rearwardly of pivot point 74, the back bracket 72 is pivotally coupled to a back support link 76 at pivot point 78, as best seen in FIG. 5. The other end of the back support link 76 is pivotally coupled to a rear bell crank 80 at pivot point 82. As best seen in FIG. 5, the rear bell crank 80 is pivotally coupled to a rear, upper end of the seat plate extension 70 at pivot point 84. The opposite end of the rear bell crank 80 is pivotally coupled to a rear toggle link 86 at pivot point 88. In some aspects, the rear bell crank 80 may support a stop pin 90 that extends away from the rear bell crank 80 and abuts the rear toggle link 86 in the closed position. Opposite pivot point 88, the rear toggle link 86 is pivotally coupled to the arm mounting plate 42 at pivot point 91 (compare FIG. 5FIG. 6).
As seen in FIGS. 4, 8, and 12, a rear pivot link 92 is pivotally coupled on one end to the trolley link 56 at pivot point 94. The opposite end of rear pivot link 92 is pivotally coupled to the seat plate extension 70 at pivot point 96. Part way between pivot point 94 and pivot point 96, the rear pivot link 92 is pivotally coupled to an ottoman drive link 98 at pivot point 100.
Turning to FIGS. 5 and 6, a front recline linkage 102 is coupled between the arm mounting plate 42 and the trolley link 56. The front recline linkage 102 includes a control link 104, a front travel link 106 and a pivot control link 108. The control link 104 is pivotally coupled to the arm mounting plate 42 at pivot point 110 on one end, and is pivotally coupled to the front travel link 106 at pivot point 112 on the other end. The end of the front travel link 106 opposite pivot point 112 is pivotally coupled to the trolley link 56 at pivot point 114. The pivot control link 108 is pivotally coupled to the front travel link 106 at pivot point 116 on one end, and is pivotally coupled to the arm mounting plate 42 at pivot point 118 on the other end. The front recline linkage 102 supports the trolley link 56 as the mechanism 26 moves the trolley link 56 forward and upward from the TV position of FIGS. 8 and 9 to the fully-reclined position of FIGS. 12 and 13.
As seen in FIGS. 5 and 6, a front pivot link 120 is pivotally coupled on one end to the trolley link 56 at pivot point 122. The opposite end of the front pivot link 120 is pivotally coupled to the seat rail 40 at pivot point 124. As the mechanism 26 moves from the closed position of FIGS. 4 and 5 to the TV position of FIGS. 8 and 9, the rear pivot link 92 and the front pivot link 120 move the seat rail 40 forwardly.
As seen in FIGS. 8A and 9, the mechanism 26 includes an ottoman linkage 130 that controls the extension of the ottoman 34 as it extends from the closed position to the TV position. The ottoman linkage 130 includes a rear ottoman link 132 that is pivotally coupled to the seat rail 40 at pivot point 134. As seen in FIG. 9, the opposite end of the rear ottoman link 132 is pivotally coupled to an outside ottoman link 136 at pivot point 138. A front ottoman link 140 is pivotally coupled to the outside ottoman link 136 at pivot point 142, spaced from pivot point 138. The other end of the front ottoman link 140 is pivotally coupled to the seat rail 40 at pivot point 144. In some aspects, pivot point 144 defines the upper extent of the MH2 measurement. In some aspects, the front ottoman link 140 and the rear ottoman link 132 are shorter than in other mechanisms. This, in part, allows the ottoman linkage to rotate farther up when in the closed position as compared to other mechanisms, allowing MH2 to be less than on other mechanisms. In some aspects, the front ottoman link 140 is less than 8 inches, or less than 7 inches, or less than 6 inches, and in some aspects, is about 5 inches long. In some aspects, the rear ottoman link 132 is less than 6.5 inches, or less than 6 inches. The other end of the outside ottoman link 136 is pivotally coupled to a main ottoman bracket 146 at pivot point 148. As seen in FIGS. 8A and 11, the main ottoman bracket 146 has in inwardly extending flange 150 that is used to mount the ottoman 34 to the main ottoman bracket 146. As seen in FIG. 8A, an inside ottoman link 152 is also pivotally coupled to the main ottoman bracket 146 at pivot point 154. The opposite end of the inside ottoman link 152 is pivotally coupled to the rear ottoman link 132 at pivot point 156. A flipper ottoman bracket 158 is also pivotally coupled to the main ottoman bracket 146 at pivot point 160. As seen in FIG. 8A, a drive link 162 is pivotally coupled on one end to the flipper ottoman bracket 158 at pivot point 164 and is pivotally coupled on the other end to the inside ottoman link 152 at pivot point 166. The flipper ottoman bracket 158 has an inwardly extending flange 168 that is used to mount a flipper ottoman 170 (see FIG. 11) to the flipper ottoman bracket 158.
The mechanism height MH2 (as seen in FIG. 2) can be measured from the lowest point of the linkage mechanism 26 (for example, in some aspects, the lowest point of the outside ottoman link 136 in the closed position of FIG. 5) to an upper point just above the upper-most point of the front pivot link 120 (with the linkage mechanism in the closed position of FIG. 5). In some aspects, MH2 can be in the range of 140-160 mm.
The front ottoman link 140 and the rear ottoman link 132 are shorter than similar links used in prior mechanisms. This results in the ottoman 34 being nearer to the end of the seat rail 40 (and the end of the seat 30) than in some prior mechanisms. As seen in FIG. 11, the distance from the front of the seat rail 28 to the back of the ottoman 34 (when in the TV position) can be seen as a distance OD. In some aspects, with the shorter front ottoman link 140 and rear ottoman link 132, the distance OD can be such that, when upholstered and finished, provides a smaller gap that does not require a mid-ottoman. In the finished, upholstered state, the distance OD allows the gap between the front of the upholstered seat and the back of the upholstered ottoman to be less than five inches. So, with the main ottoman 34 this near the end of the seat rail 40, there is not a need for an auxiliary ottoman in the gap between the ottoman 34 and the seat 30. To add length to support a user's lower legs, the flipper ottoman 170 is extended in front of the ottoman 34. The flipper ottoman 170 allows the overall extension from the back of the seat 30 to the front of the flipper ottoman 170 (labeled EXT in FIG. 11) to be of a length comfortable for users. In some aspects, the distance EXT is about forty inches. The shorter rear ottoman link 132 and front ottoman link 140 also allow the ottoman 34 to be further off the floor in the closed position (allowing a higher leg height (LH), a lower seat height (SH) and/or a reduced mechanism height (MH1 or MH2) while hiding the links of the mechanism 26 from view (hidden by the side frame 24 without needing to alter the lower edge of the side frame 24). This allows designers of high-leg seating more flexibility and a clean look.
As described above, a rear stabilizer tube 66 extends between opposing rear travel links 52 at the rear of the mechanism 26. Similarly, a front stabilizer tube 172 is coupled to, and extends between, opposing trolley links 56. As best seen in FIG. 8, the rear stabilizer tube 66, in some aspects, includes a section with an upward bend in the middle. Further, in some aspects, the front stabilizer tube 172 includes a section with a downward bend in the middle. The bends in the rear stabilizer tube 66 and the front stabilizer tube 172 provide clearance for the motor 64. As described above, the motor 64 is pivotally coupled on one end to the rear motor tube 63. The other end of the motor 64 is pivotally coupled to a front motor tube 174. In some aspects, the front motor tube 174 includes end brackets 176. The end bracket 176 is fixedly coupled to a motor drive link 178. The end of the motor drive link 178 opposite the end bracket 176 is pivotally coupled to the rear ottoman link 132 at pivot point 180, as seen in FIG. 8A. About midway between the two ends of the motor drive link 178, a motor control link 182 is pivotally coupled to the motor drive link 178 at pivot point 184. The opposite end of the motor control link 182 is pivotally coupled to the front ottoman link 140 at pivot point 186. The motor drive link 178 is thus coupled to both the rear ottoman link 132 and the front ottoman link 140 (via the motor control link 182). As the rear ottoman link 132 and the front ottoman link 140 rotate from the closed position to the TV position, the motor drive link 178 and the motor control link 182 cooperate to restrict the up-and-down movement of the front motor tube 174 (and thus the motor 64). This results in a more linear movement of the front motor tube 174 and the motor 64 as the motor 64 moves the mechanism 26 from the closed position to the TV position, requiring less vertical space for the motor 64. In other words, the front of the motor 64, where it mounts to the front motor tube 174, does not swing down and then back up as much as it would if it were coupled to only the rear ottoman link 132 or the front ottoman link 140. This also allows for a very compact, powered mechanism, allowing the motor 64 to clear the front stabilizer tube 172, while also allowing a very shallow downward bend in the front stabilizer tube 172, such that the front stabilizer tube 172 remains hidden from view in the closed position.
Further, as described above the rear recline linkage 44 is moved upwardly and rearwardly compared to prior mechanisms, more effectively utilizing the space rearward of the seat rail 40. As seen in FIG. 6, the rear recline linkage 44 (including the control link 50, the rear travel link 52 and the pivot control link 60) are all rearwardly of pivot point 74 when the mechanism 26 is in the closed position of FIG. 6. In some aspects, the rear recline linkage 44 is rearwardly of a notch 190 (see FIG. 7) in the seat frame 28. Additionally, at least some portion of the rear recline linkage 44 is above the seat rail 40 when the mechanism 26 is in the closed position. The mechanism height (MH1 or MH2) is reduced, in part, by moving the rear recline linkage 44 to this location (allowing a higher leg height (LH), a lower seat height (SH) or a combination thereof while hiding the links of the mechanism 26 from view). This again allows designers of high-leg seating more flexibility and a clean look.
As would be understood by those in the art, the motor 64 may be activated to move the seating unit 20 between the closed position of FIGS. 2-7 to the TV position of FIGS. 8-11 and to the fully-reclined position of FIGS. 12-15 (and then reversing the movement back to the closed position). Using the mechanism 26, furniture designers and manufacturers can design a high-leg seating unit 20 with a higher leg height (LH), a lower seat height (SH) or some combination thereof due to the reduced mechanism height (MH1 or MH2). In some aspects, MH2 is in the range of 140 mm to 160 mm, compared to prior mechanisms of 170 mm or more.
In an alternative embodiment, as shown in FIGS. 16-21, a mechanism 200 is depicted that is usable on a chair designed to have a stationary seat and back, with a moveable ottoman. FIGS. 16-18 depict the mechanism 200 in a closed position, and FIGS. 19-21 depict the mechanism 200 in an extended or TV position. The mechanism 200 provides a compact and lightweight design, usable on a chair with high-leg styling in an unobtrusive way.
As seen in FIG. 16, the mechanism 200 includes a mounting plate 202 that is used to couple the mechanism 200 to the sides or arms of a chair on which mechanism 200 is used. In some aspects, the mounting plate 202 has a series of mounting holes 204 (as best seen in FIG. 18) to couple the mounting plate 202 to the sides or arms of the chair. As seen in FIG. 16, a motor tube 206 may be coupled to, and extend between, opposing mounting plates 202 with end brackets 208. The end brackets 208 may be fixedly coupled to the motor tube 204, such as by welding, and to the mounting plate 202, such as by bolting or riveting. It should be understood that FIGS. 16-21 show a mechanism with only one side of the linkage for clarity, but that the other side would be a mirror image. As seen in FIGS. 16 and 19, a motor bracket 210 is fixedly coupled to the motor tube 204, generally midway along the motor tube 204. The motor bracket 210 is used to pivotally couple an ottoman motor to the motor tube 206 (the ottoman motor is not shown, but its location and function would be understood by those of skill in the art).
As best seen in FIGS. 20 and 21, a rear ottoman link 212 is pivotally coupled to the mounting plate 202 at pivot point 214. The end of the rear ottoman link 212 opposite pivot point 214 is pivotally coupled to an inside ottoman link 216 at pivot point 218. Between pivot point 212 and pivot point 218, the rear ottoman link 212 is pivotally coupled to a motor drive link 220 at pivot point 222. The outer end of the motor drive link 220 is fixedly coupled to a front motor tube 224. In some aspects, the front motor tube 224 is coupled to the motor drive link 220 via a pair of end brackets 226 fixed to the front motor tube 224, such as by welding. The end brackets 226 can, in turn, be fixed to the motor drive link 220, such as by bolting or riveting. A front motor bracket 228 is fixedly coupled to the front motor tube 224, generally midway along the front motor tube 224, and in alignment with the rear motor bracket 210. As would be understood by those of skill in the art, a motor could be pivotally mounted between the rear motor bracket 210 and the front motor bracket 228.
As seen in FIG. 20, the motor drive link 220 is also pivotally coupled to a motor control link 230 at pivot point 232. The end of the motor control link 230 opposite pivot point 232 is pivotally coupled to a front ottoman link 234 at pivot point 236. As seen in FIG. 20, the upper end of the front ottoman link 234 is pivotally coupled to the mounting plate 202 at pivot point 238. The linkage of the motor drive link 220 and the motor control link 230 thus couples the rear ottoman link 212 to the front ottoman link 234. As seen in FIG. 21, the end of the front ottoman link 234 opposite pivot point 238 is pivotally coupled to an outside ottoman link 240 at pivot point 242. The rear ottoman link 212 is also pivotally coupled to the outside ottoman link 240, at pivot point 244. In some aspects, pivot point 238 defines the upper extent of the MH2 measurement, and the lowest extent of MH2 is lowest extent of the mechanism 200 when in the closed position. In some aspects, the front ottoman link 234 and the rear ottoman link 212 are shorter than in other mechanisms. This, in part, allows the ottoman linkage to rotate farther up when in the closed position as compared to other mechanisms, allowing MH2 to be less than on other mechanisms. In some aspects, the length of the front ottoman link 234 is less than 8 inches, or less than 7 inches, or less than 6 inches, and in some aspects, is about 5 inches long. In some aspects, the length of the rear ottoman link 212 is less than 6.5 inches, or less than 6 inches.
The outside ottoman link 240 extends from pivot point 244 and is pivotally coupled at its other end to an ottoman bracket 250 at pivot point 252. As seen in FIG. 20, the ottoman bracket 250 is also pivotally coupled to the inside ottoman link 216 at pivot point 254. Also, as seen in FIG. 21, the ottoman bracket 250 is pivotally coupled to a flipper ottoman bracket 256 at pivot point 258. The flipper ottoman bracket 256 is also pivotally coupled to a flipper drive link 260 at pivot point 262. The other end of the flipper drive link 260 is pivotally coupled to the outer end of the inside ottoman link 216 at pivot point 264.
With an ottoman motor pivotally coupled between the rear motor bracket 210 and the front motor bracket 228, the mechanism 200 can be moved from the stowed position of FIGS. 16-18, with the ottoman bracket 250 and the flipper ottoman bracket 256 in a closed position, to the extended or TV position of FIGS. 19-21, with the ottoman bracket 250 and the flipper ottoman bracket 256 in the extended position. When in the closed position, the mechanism 200 offers a compact design, requiring little vertical space from pivot point 238 to the lowest extent of the mechanism 200 (e.g., the bottom of the outside ottoman link 240 in the closed position). The linkage of the motor drive link 220, the motor control link 230 and their connection between the front ottoman link 234, the rear ottoman link 212 and the motor drive tube 224 drive the motor drive tube 224 in a nearly linear motion (without the motor drive tube 224 arcing downward and the upward). The mechanism 200 thus offers furniture manufacturers the option of offering an extending ottoman (supported by ottoman bracket 250 and flipper ottoman bracket 256), with a stationary seat and back, all in a compact, lightweight design, which may be offered on a high-leg styled chair. For context, the mechanism 200 is shown in FIG. 22 within the framing of a seat. FIG. 22 shows a typical bracing support 300 generally midway along the seat frame. By employing shorter front ottoman links 234, and rear ottoman links 212, the mechanism can rotate more in going to the closed position, without running into the support 300. The additional rotation allows the mechanism 200 to be used on a chair with a higher leg distance (LH) and a lower seat height (SH) if desired when styling the chair (or on a chair with a comparable SH, but a higher LH), because the mechanism 200 has a lower mechanism height (MH2). As shown in FIG. 17, the front ottoman link 234, in the closed position, may form an angle β relative to horizontal that is less than in prior mechanisms, due to the additional rotation allowed by the shorter front ottoman link 234. In some aspects, the angle β is less than 50 degrees, and in some aspects, is about 48 degrees. As also shown in FIG. 17, the rear ottoman link 212, in the closed position, may form an angle α relative to horizontal that is less than in prior mechanisms, due to the additional rotation of the rear ottoman link 212. In some aspects, the angle α is less than 45 degrees, or less than 40 degrees, or less than 35 degrees and in some aspects is about 30 degrees. The ottoman linkage 130 discussed above with respect to FIGS. 2-15 has similar ranges for the angles of the front and rear ottoman links.
FIGS. 23-37 illustrate another embodiment of a mechanism 426 for use on a high-leg chair. Unlike the mechanism of FIGS. 2-22, the mechanism 426 utilizes a six-bar ottoman linkage 530 (as seen in FIG. 30 and further described below), rather than a four-bar ottoman linkage (such as ottoman linkage 130 discussed above). The mechanism 426 retains the advantages discussed above, allowing use on a wall-proximity, high-leg chair, while still providing a low-profile that can be largely hidden from view by other aspects of the chair. The use of the six-bar ottoman linkage 530 allows the ottoman to be extended farther away from the seat of the chair, as might be desired by some users.
While many of the same links are utilized in the mechanism 426 as those described above with respect to FIGS. 2-22, a complete description of mechanism 426 follows. A seating unit 420 is shown in FIG. 23 in a closed position. The seating unit 420, in some aspects, has legs 422 that support the remainder of the seating unit 420 above the floor or other support surface. The seating unit 420 may also include a side frame 424 that supports the linkage mechanism 426 (shown in more detail in other figures). The seating unit 420, in some aspects, may also have arms (not shown). The mechanism 426 is coupled to a seat frame 428 that supports a seat 430, a back frame 432 (which supports upholstery that is not shown) and an ottoman 434 (which may be configured in multiple support pieces as shown FIG. 24, which is discussed further below). The mechanism 426 allows the seating unit 420 to use what is known as “high-leg” styling with a very compact mechanism height that allows the side frame 424 to substantially obscure mechanism 426 from view, and that allows the chair to be placed close to an adjacent wall (a wall-proximity chair). As seen in FIG. 23, the legs 422 support the seating unit above the floor at a leg height (LH) measured from the floor to the lower edge of the side frame 424. In some aspects, the leg height is between seven and eight inches. In some aspects, the seat 430 is positioned above the floor at a seat height (SH) that may be about 20 inches. The space between the lower edge of the side frame 424 and the lower edge of the seat frame 428 is occupied by the mechanism 426. Because the seat frame 428 typically sits at an angle, the space available for the mechanism height (MH) may be measured from different points. In some aspects, a mechanism height (MH2) may be the distance from the lower edge of the mechanism 426 to a point 544 (discussed further below) on a seat rail 440 that obscures the majority of the mechanism 426. With a very compact mechanism 426, designers of the seating unit 420 are able to provide a higher leg distance (LH) and a lower seat height (SH) if that is desired, while still offering a wall-proximity chair. This is made possible by the mechanism 426 with a lower mechanism height (MH) than was previously possible. For example, in some aspects, MH2 is in the range of about 160 mm to 180 mm, compared with prior mechanisms utilizing a six bar ottoman linkage, where a comparable MH2 is 200 mm or more. The mechanism 426 thus allows a three-way reclining (moving between closed, TV and fully-reclined positions), wall-proximity chair, with a seat height (SH) comparable to other chairs in the market, but with a higher leg height (LH), while offering a mechanism that is hidden from view in the closed position, and while offering a six-bar ottoman linkage 530 that extends farther away from the seat 430.
As shown in FIG. 26, the mechanism 426 includes an arm mounting plate 442 that is used to couple the mechanism 426 to the side frame 424. A rear recline linkage 444 is pivotally coupled to the arm mounting plate 442 at pivot points 446 and 448. The rear recline linkage 444 includes a control link 450 that is pivotally coupled to the arm mounting plate at pivot point 446. As seen in FIG. 27, the control link 450 (opposite pivot point 446) is pivotally coupled to a rear travel link 452 at pivot point 454. The other end of the rear travel link 452 is pivotally coupled to a trolley link 456 at pivot point 458. Generally mid-way between pivot point 454 and pivot point 458, the rear travel link 452 is pivotally coupled to a pivot control link 460 at pivot point 462. The end of the pivot control link 460 opposite pivot point 462 is pivotally coupled to the arm mounting plate at pivot point 448. As will be further discussed below, the rear recline linkage 444 (including the control link 450, the rear travel link 452 and the pivot control link 460) is located more rearwardly, and higher, than in previous mechanisms, allowing for a very compact mechanism 426.
As seen in FIG. 25, a rear motor tube 463 is coupled between opposing arm mounting plates 442. The rear motor tube 463 pivotally supports a motor 464 as more-fully described below. Additionally, a rear stabilizer tube 466 is fixedly coupled to the lower end of rear travel link 452 with a flange 468 (as seen in FIG. 28). The rear stabilizer tube 466 extends between opposing rear travel links 452.
As seen in FIGS. 25 and 26, a seat plate extension 470 is fixedly coupled to the seat rail 440. The combination of the seat rail 440 and the seat plate extension 470 may be referred to as a seat plate. The seat plate extension 470 generally extends rearwardly and upwardly from the seat rail 440. A back bracket 472 is pivotally coupled to the seat plate extension 470 at pivot point 474. The back bracket 472 is used to support the back frame 432 of the seating unit 420, and the back frame 432 moves in connection with the movement of the back bracket 472. Rearwardly of pivot point 474, the back bracket 472 is pivotally coupled to a back support link 476 at pivot point 478, as best seen in FIG. 26. The other end of the back support link 476 is pivotally coupled to a rear bell crank 480 at pivot point 482. As best seen in FIG. 26, the rear bell crank 480 is pivotally coupled to a rear, upper end of the seat plate extension 470 at pivot point 484. The opposite end of the rear bell crank 480 is pivotally coupled to a rear toggle link 486 at pivot point 488. In some aspects, the rear bell crank 480 may support a stop pin 490 that extends away from the rear bell crank 480 and abuts the rear toggle link 486 in the closed position. Opposite pivot point 488, the rear toggle link 486 is pivotally coupled to the arm mounting plate 442 at pivot point 491 (compare FIG. 26FIG. 27).
As seen in FIGS. 25, 29, and 34, a rear pivot link 492 is pivotally coupled on one end to the trolley link 456 at pivot point 494. The opposite end of rear pivot link 492 is pivotally coupled to the seat plate extension 470 at pivot point 496. Part way between pivot point 494 and pivot point 496, the rear pivot link 492 is pivotally coupled to an ottoman drive link 498 at pivot point 500.
Turning to FIGS. 26 and 27, a front recline linkage 502 is coupled between the arm mounting plate 442 and the trolley link 456. The front recline linkage 502 includes a control link 504, a front travel link 506 and a pivot control link 508. The control link 504 is pivotally coupled to the arm mounting plate 442 at pivot point 510 on one end, and is pivotally coupled to the front travel link 506 at pivot point 512 on the other end. The end of the front travel link 506 opposite pivot point 512 is pivotally coupled to the trolley link 456 at pivot point 514. The pivot control link 508 is pivotally coupled to the front travel link 506 at pivot point 516 on one end, and is pivotally coupled to the arm mounting plate 442 at pivot point 518 on the other end. The front recline linkage 502 supports the trolley link 456 as the mechanism 426 moves the trolley link 456 forward and upward from the TV position of FIGS. 29-33 to the fully-reclined position of FIGS. 34-37.
As seen in FIG. 27, a front pivot link 520 is pivotally coupled on one end to the trolley link 456 at pivot point 522. The opposite end of the front pivot link 520 is pivotally coupled to the seat rail 440 at pivot point 524. As the mechanism 426 moves from the closed position of FIGS. 26 and 27 to the TV position of FIGS. 31 and 32, the rear pivot link 492 and the front pivot link 520 move the seat rail 440 forwardly.
As seen in FIGS. 30-35, the mechanism 426 includes an ottoman linkage 530 that controls the extension of the ottoman as it extends from the closed position to the TV position. The ottoman linkage 530 includes a rear ottoman link 532 that is pivotally coupled to the seat rail 440 at pivot point 534. The end of the rear ottoman link 532 near pivot point 534 is pivotally coupled to the ottoman drive link 498 at pivot point 535. As seen in FIG. 30, the opposite end of the rear ottoman link 532 is pivotally coupled to an upper ottoman link 536 at pivot point 538. A front ottoman link 540 is pivotally coupled to the upper ottoman link 536 at pivot point 542, spaced from pivot point 538. One end of the front ottoman link 540 is pivotally coupled to the seat rail 440 at pivot point 544. In some aspects, pivot point 544 defines the upper extent of the MH2 measurement. In some aspects, the front ottoman link 540 and the rear ottoman link 532 are shorter than in other mechanisms. This, in part, allows the ottoman linkage 530 to rotate farther up when in the closed position as compared to other six-bar ottoman linkages, allowing MH2 to be less than on other mechanisms. In some aspects, the front ottoman link 140 is less than 8.5 inches, or less than 8 inches, or less than 7.5 inches, and in some aspects, is about 7.375 inches long. In some aspects, the rear ottoman link 532 is less than 6.5 inches, or less than 6 inches, and in some aspects is about 5.875 inches long. The other end of the upper ottoman link 536 is pivotally coupled to a mid-ottoman bracket 546 at pivot point 548. As seen in FIG. 30, the mid-ottoman bracket 546 has an inwardly extending flange 550 that is used to mount a mid-ottoman to the mid-ottoman bracket 546. An outside ottoman link 552 is also pivotally coupled to the mid-ottoman bracket 546 at pivot point 554. One end of the outside ottoman link 552 is pivotally coupled to the front ottoman link 540 at pivot point 556. The other end of the outside ottoman link 552 is coupled to a main ottoman bracket 558 at pivot point 560. Like the mid-ottoman bracket 546, the main ottoman bracket 558 has an inwardly extending flange 562. The flange 562 is used to mount a main ottoman to the main ottoman bracket 558. A lower ottoman link 564 extends between the mid-ottoman bracket 546 and the main ottoman bracket 558. More specifically, the lower ottoman link 564 is pivotally coupled on one end to the mid-ottoman bracket 546 at pivot point 566, and to the main ottoman bracket 558 at pivot point 568. Beyond pivot point 568, the lower ottoman link 564 is pivotally coupled to a flipper ottoman bracket 570 at pivot point 572. The flipper ottoman bracket 570 also has an inwardly extending flange 574 used to support a flipper ottoman. A drive link 576 is pivotally coupled to the flipper ottoman bracket at pivot point 578. The other end of the drive link 576 is pivotally coupled to the main ottoman bracket 558 at pivot point 580.
As described above, a rear stabilizer tube 466 extends between opposing rear travel links 452 at the rear of the mechanism 426. Similarly, a front stabilizer tube 582 is coupled to, and extends between, opposing trolley links 456. As best seen in FIG. 25, the rear stabilizer tube 466, in some aspects, includes a section with an upward bend in the middle. Further, in some aspects, the front stabilizer tube 582 includes a section with a downward bend in the middle. The bends in the rear stabilizer tube 466 and the front stabilizer tube 582 provide clearance for the motor 464. As described above, the motor 464 is pivotally coupled on one end to the rear motor tube 463. As seen in FIG. 30, the other end of the motor 464 is pivotally coupled to a front motor tube 584. In some aspects, the front motor tube 584 includes end brackets 586. The end bracket 586 is fixedly coupled to the front ottoman link 540. As the rear ottoman link 532 and the front ottoman link 540 rotate from the closed position to the TV position, the front motor tube 584 and the motor 464 swing slightly downwardly and then upwardly as the motor 464 moves the mechanism 426 from the closed position to the TV position. This motion is slightly different than that described above with respect to FIGS. 2-22, due to the movement of the six-bar linkage, and the coupling of the front motor tube 584 to the front ottoman link 540.
Further, as described above the rear recline linkage 444 is moved upwardly and rearwardly compared to prior mechanisms, more effectively utilizing the space rearward of the seat rail 440. As seen in FIG. 27, the rear recline linkage 444 (including the control link 450, the rear travel link 452 and the pivot control link 460) are all rearwardly of pivot point 474 when the mechanism 426 is in the closed position of FIG. 27. Additionally, at least some portion of the rear recline linkage 444 is above the seat rail 440 when the mechanism 426 is in the closed position. The mechanism height (MH2) is reduced, in part, by moving the rear recline linkage 444 to this location (allowing a higher leg height (LH), a lower seat height (SH) or a combination thereof while hiding the links of the mechanism 426 from view). This again allows designers of high-leg seating more flexibility and a clean look.
As would be understood by those in the art, the motor 464 may be activated to move the seating unit 420 between the closed position of FIGS. 23-28 to the TV position of FIGS. 29-33 and to the fully-reclined position of FIGS. 34-37 (and then reversing the movement back to the closed position). Using the mechanism 426, furniture designers and manufacturers can design a high-leg seating unit 420 with a higher leg height (LH), a lower seat height (SH) or some combination thereof due to the reduced mechanism height (MH2). In some aspects, MH2 is in the range of 160 mm to 180 mm, compared to prior mechanisms utilizing a six bar ottoman linkage of 200 mm or more.
The mechanism height MH2 (as seen in FIG. 23) can be measured from the lowest point of the linkage mechanism 426 (for example, in some aspects, the lowest point of the mid-ottoman bracket 546 in the closed position of FIG. 27) to an upper point just above the upper-most point of the front ottoman link 540 (near pivot point 544)(with the linkage mechanism in the closed position of FIGS. 23 and 27). In some aspects, MH2 can be in the range of 160-180 mm. For context, portions of the mechanism 426 are shown in FIG. 24A in an enlarged view. By employing shorter front ottoman links 540, and rear ottoman links 532, the mechanism 426 can rotate more in going to the closed position, without running into the support framing of the chair 420. The additional rotation allows the mechanism 426 to be used on a chair with a higher leg distance (LH) and a lower seat height (SH) if desired when styling the chair (or on a chair with a comparable SH, but a higher LH), because the mechanism 426 has a lower mechanism height (MH2). As shown in FIG. 24A, the front ottoman link 540, in the closed position, may form an angle β relative to horizontal that is less than in prior mechanisms, due to the additional rotation allowed by the shorter front ottoman link 540. In some aspects, the angle β is less than 50 degrees, or less than 45 degrees, or less than 40 degrees, and in some aspects, is about 39 degrees. As also shown in FIG. 24A, the pivot points on the rear ottoman link 532, in the closed position, may form an angle α relative to horizontal that is less than in prior mechanisms, due to the additional rotation of the rear ottoman link 532. In some aspects, the angle α is less than 45 degrees, or less than 40 degrees, or less than 35 degrees and in some aspects is about 34 degrees.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages, which are obvious and inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
Patent Application
20240315452
