Patent Application
20140091601
The present invention is directed to a power mechanism for driving the movable elements of a recliner. Specifically, the present invention is directed to a power mechanism having a reverse drive assembly with the motor mounted proximate to the rear of the recliner to simplify manufacturing and assembly of the recliner.
A recliner typically comprises a back rest that rotates downward to lower the user's back and head from an upright position to more a reclined position. Similarly, recliners also often comprise a deployable ottoman that has a leg rest that rotates outwardly to elevate the user's legs. Certain recliners often also shift the seat box forward to provide room behind the recliner for the lowered back rest. The recliners can also rotate the seat box to elevate the front of the seat box relative to the rear of the seat box to further position the user in a more comfortable reclined position. The back rest, ottoman and seat box of certain recliners are operably linked to a single rotating driving axle that is rotated by a drive assembly to move the various components such that the moving components can be operated simultaneously. The drive axle can also be moved horizontally to provide shift the seat box forward and extend the leg rest outwards from the seat box.
In operation, the drive axle is rotated in a first direction to lower back rest while rotating the leg rest of the ottoman into the reclined position. The drive axle can then be shifted forward to shift the seat box forward and extend the leg rest from the seat box of the recliner. The drive axle can then be shifted backwards and rotated in the opposite direction to return the moving components of the recliner to their original positions.
In certain recliners, such as shown in
The drive assembly often comprises a motor at the end of the horizontal track proximate to the front of the recliner for pulling or pushing the traveler down the track. The front mounted motor is advantageous as the horizontal track is typically positioned beneath the seat box and remains fixed in place even as the various components of the recliner are moving. In particular, shifting the seat box forward to accommodate the reclining back rest can move the edges of the seat box such that the edges of the seat box intersect the horizontal track and motor. A front mounted motor provides more clearance for the motor to avoid the edge of the seat box as the seat box moves forward. Moreover, as the leg rest of the ottoman assembly typically defines the front face of the seat box, the simultaneous extension of the ottoman assembly provides a gap in the front of the seat box to provide additional clearance for the motor. Also, the elevation of the front portion of the seat box also reduces the likelihood that the seat box will become caught on the motor.
While a front mounted motor provides numerous advantages when operation the recliner, the inherent drawback of front mounted motors is that the motor placement is substantially more challenging to manufacture and assemble. A primary design consideration for motor powered recliners is positioning the wiring for the motor such that the power plug extends from the rear of the recliner. The rearward power plug reduces the likelihood that the plug will be tripped over and presents a more aesthetically appealing appearance. However, front mounting the motor requires that the wiring for the motor must be threaded through the plurality of linkages used to operate the moving parts to reach the motor from the rear of the recliner. The wiring must also be secured to prevent the wiring from catching on the linkages during operation of the assembly. The arduous task of threading and securing the wiring adds considerable time to the manufacturing process and can be easily done incorrectly resulting in damage to the wiring or linkages if the linkages engage an improperly secured or threaded wiring.
A similar drawback is that front mounted motors often results in the motor being visible from the front of the recliner through the opening left by the foot rest when the ottoman assembly is deployed. In addition to being aesthetically unpleasing, the exposed motor and/or wiring could become damaged.
As a result, there is a need for a means to operate a recliner that is reduces the time and difficulty required to manufacture the power mechanism for the recliner while maintaining an aesthetically pleasing appearance.
The present invention is directed to a recliner having a power mechanism comprising a drive axle and a reverse drive assembly in which the motor is mounted at the end of the horizontal track proximate to the rear of the recliner. The reverse drive assembly reduces the effort and time required to assemble and wire the recliner as the motor is positioned proximate to the rear of the recliner minimizing the distance between the power plug and the motor. As such, the wiring linking the motor to the power plug does not have to be threaded through the linkages of the recliner or secured to avoid engaging the linkages. Instead, the wiring can be directly attached to the motor without fear of the wiring being caught on the linkages during operation, thereby substantially reducing the time required to manufacture and assemble the recliner. Also, the rear mounted motor makes the motor less visible when the ottoman assembly is extended. Unlike conventional front mounted motors, the rear mounted motor of the present invention protrudes from the rear of the recliner rather than the front of the recliner when the seat box is shifted forward such that the motor is less visible and less likely to be damaged.
The reverse drive assembly can also further comprise at least one “reverse” transfer linkage bent at a predetermined angle. In operation, the reverse drive assembly must rotate the drive axle a predetermined rotational distance to operate the ottoman assembly and back rest. The reverse transfer linkage is bent further than conventional linkages such that the traveler requires shorter horizontal travel distance to rotate the drive axle the necessary rotational distance. In one aspect, the predetermined angle can comprise a 110 to 150 degree angle. In yet another aspect, the predetermined angle can be bent to comprise a 130 degree angle. The reverse mounted motor allows for a deeper bend in the linkage as the rear mounted motor does not interfere with the transfer linkages as the traveler moves along the horizontal track. In particular, as the traveler approaches the end of the track, the linkage extends over the end of the track potentially impacting a front mounted motor.
Moreover, the shorter horizontal travel distance allows for a shorter horizontal track providing clearance at the rear of the horizontal track for the motor to be rear mounted with sufficient clearance for the seat box. As the drive axle must be moved a predetermined distance horizontally, the length of the horizontal track that must traveled by the traveler to push the drive axle the necessary horizontal distance cannot be shortened. Accordingly, only the length of the horizontal track for rotating the drive axle can be shortened. The bend in the reverse transfer linkage is set to shorten the length of the horizontal track corresponding to rotation of the drive axle such that the motor can be placed behind the traveler.
A power mechanism, according to an embodiment of the present invention, can comprise a drive axle, a reverse drive assembly, a horizontal track and a traveler. The reverse drive assembly can further comprise a motor and a worm gear positionable within the horizontal track and rotatable by the motor to move the traveler along the horizontal track. The motor is affixed to one end of the horizontal track, wherein the horizontal track is positioned perpendicular to a rotatable drive axle for a recliner such that the motor is positioned proximate to the rear of the recliner. The traveler can further comprise at least one reverse transition linkage having an L-shaped bracket at one end of the linkage for rotatably engaging the linkage to the drive axle.
In one aspect, the horizontal track can define a first segment corresponding to the length of the horizontal track that is traveled by the traveler to rotate drive axle a predetermined rotational distance and define a second segment corresponding to the length of the horizontal track traveled by the traveler to move the drive axle a predetermined horizontal distance. The predetermined rotational distance corresponds to the necessary rotation for the drive axle to extend the ottoman assembly and/or recline the back rest. The predetermined horizontal distance corresponds to the horizontal distance the seat box is shifted forward to provide clearance for the reclining back rest. In this configuration, each reverse transfer linkage is bent at a predetermined angle to shorten the first segment of the horizontal track enough to provide at least enough clearance at the rear of the horizontal track to mount the motor at the rear of the horizontal track while still rotating the drive axle the necessary rotational distance.
A recliner, according to an embodiment of the present invention, comprises a seat box, a back rest, an ottoman assembly, a base and a power mechanism. The power mechanism comprises a drive axle rotated and moved horizontally by a traveler traveling along a horizontal track. The drive axle is rotatably mounted to the seat box, wherein moving the drive axle horizontally with the traveler shifts the seat box horizontally with the drive axle. In one aspect, the seat box can further comprise a notch in the rear edge of the seat box to provide clearance for the rear-mounted motor as the seat box slides forward. Similarly, the ottoman assembly further comprises a leg rest and at least one scissor linkage assembly having a lever linkage engaged to the drive axle such that rotating the drive axle extends the scissor linkage assembly to position the leg rest generally parallel to the top of the seat rest.
The above summary of the various representative aspects of the invention is not intended to describe each illustrated aspect or every implementation of the invention. Rather, the aspects are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these aspects.
Still other objects and advantages of the present invention and methods of construction of the same will become readily apparent to those skilled in the art from the following detailed description, wherein only the preferred embodiments are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments and methods of construction, and its several details are capable of modification in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
As shown in
As shown in
As shown in
The horizontal track 36 is mounted to the end rails 30 such that the horizontal track 36 extends between the end rails 30 in parallel to the longitudinal rails 28. The motor 48 is positioned at the end of the horizontal track 36 proximate to the rear of the seat box 26. In one aspect, the horizontal track 36 defines a first segment 52 and a second segment 54.
In operation, the traveler 38 is operably engaged to the worm gear 50, such that rotation of the worm gear 50 by the motor 48 in a first direction pushes the traveler 38 down the horizontal track 36 in the first direction, toward the front of the recliner 20. Rotating the worm gear 50 in the opposite second direction pulls the traveler 38 in the opposite direction. Moving the traveler 38 in the first direction through the first segment 52 applies a tangential pushing force to the arm portion 44 to rotate the drive axle 34 in a first direction until the drive axle 34 has rotated a predetermined rotational distance. The drive axle 34 remains substantially longitudinally fixed relative to the traveler 38 during longitudinal movement of the traveler 38. The length of the first segment 52 corresponds to the necessary horizontal travel distance of the traveler 38 to rotate the drive axle 34 the necessary rotational distance. This distance substantially effectuates to the extension of the ottoman assembly 70. Continuing the movement of the traveler 38 into the second segment 54 maintains the rotation of the drive axle 34, in that the drive axle 34 substantially ceases rotation, while applying an axial pull force to the arm portion 44 to move the drive axle 34 horizontally with the traveler 38. Similarly, moving the traveler 38 in the second direction through the second segment 54 moves or pushes the drive axle 34 horizontally in the opposite direction until the traveler 38 reaches the first segment 52. Pulling the traveler 38 in the second direction through the first segment 52 applies a tangential pulling force to the arm portion 44 to rotate the drive axle 34 in an opposite second direction until the drive axle 34 is returned to the original position.
The seat box 26 further comprises a box frame 60, at least two forward swing linkage assemblies 62 and at least two rear swing linkages 64. Each forward swing linkage assembly 62 comprises scissoring linkages 66 movable between a generally bent orientation and a generally elongated orientation. The seat box 26 also further comprises at least one drive axle bracket 68 for rotatably receiving the drive axle 34. In the embodiment shown, the drive axle bracket further serves as the seat mounting plate. As shown in
In operation, moving the traveler 38 in the first direction through the second segment 54 moves the seat box 26 forward relative to the base 22. As shown in
As shown in
In operation, moving the traveler 38 through the first segment 52 in the first direction rotates the drive axle 34 in the first direction applying a pushing force on the leg rest 72 through the lever assembly 78 to extend the extension assembly 74 and position the leg rest 72 in an orientation generally parallel to the top of the seat box 26. Similarly, moving the traveler 38 in the second direction through the first segment 52 rotates the drive axle 34 in the second direction applying a pulling force on the leg rest 72 through the lever assembly 78 to retract the extension assembly 74 to return the leg reset 72 to the original position. In one aspect, the ottoman assembly 74 can be mounted to the seat box 26 on a floating assembly such that the horizontal movement of the drive axle 34 extends the leg rest 72 out from the seat box 26.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim
All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.
This application claims priority to U.S. Provisional Application No. 61/708,993, filed Oct. 2, 2012 and U.S. Provisional Application No. 61/802,025, filed Mar. 15, 2013, each of which is hereby fully incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61708993 | Oct 2012 | US | |
| 61802025 | Mar 2013 | US |
