BACKGROUND
Recliners are generally well known in the furniture industry. The term recliner is used throughout this description to describe articles of furniture that include a reclining mechanism. Generally recliners having reclining mechanisms are chairs that allow the user to recline and are equipped with one or more extendable ottomans. Recliners are often in the form of a plush chair, however, they might also take the form of an oversized seat, a seat-and-a-half, a love seat, a sofa, a sectional, and the like. Recliners are known in both a manual configuration (where the user releases the reclining mechanism from a closed position to a TV position, and moves the reclining mechanism from the TV position to a full recline position) and a motorized version (where a motor is used to move the mechanism between the various positions).
The reclining motion is typically achieved in recliners with a linkage mechanism that is coupled to a base. The linkage mechanisms found in recliners in the art include a plurality of interconnected links that provide one or more mechanisms for extending and retracting a footrest, and reclining and returning to upright a back of the recliner. Typically, recliners known in the art provide three positions: an upright seated position with the footrest retracted beneath the chair (the “closed position”); a television viewing position in which the chair back is slightly reclined but still provides a generally upright position with the footrest extended (the “TV position”), and a fully reclined position in which the chair back is reclined an additional amount farther than in the TV position but still generally inclined with respect to the seat of the chair and with the footrest extended (the “fully reclined position”). Most recliner mechanisms provide a coordinated movement of the seat, the ottoman and the back as the recliner moves between the previously described positions. There are now some lift chair recliners that allow the back, the seat and the ottoman to be moved individually, and independently. However, these mechanisms are heavy and somewhat complicated. Moreover, to allow independent movement, the various motors used may need to be programmed for coordinated movement, such that as one motor moves, the other motor(s) may also have to move to compensate for potential misalignment of other linkages. Without this programmed, coordinated movement, the force of the motor may cause the linkage to bind, and could potentially damage the links in the linkages, such as by bending.
It would be desirable to provide a recliner mechanism that could be used on a standard recliner, without the unnecessary weight and additional linkage of a lift chair, while still offering independent movement of the back, the seat pitch and the ottoman extension. In other words, it would be desirable to provide a recliner mechanism with independent movement of the seat pitch, the back and the ottoman extension in a simple geometry that prevents any potential binding issues, without any need for special programming of the motors.
BRIEF SUMMARY
Embodiments of the invention are defined by the claims below, not this summary. A high-level overview of various aspects of the invention are provided here for that reason, to provide an overview of the disclosure, and to introduce a selection of concepts that are further described below in the detailed-description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in isolation to determine the scope of the claimed subject matter.
In aspects of the invention, a recliner mechanism is provided with independently operable motors. Each motor may effect an independent movement. For example, three motors may be provided: a seat pitch motor causing a rotation of the seat to change the seat pitch in relation to the support surface on which the recliner sits; an ottoman motor to extend and retract an ottoman; and a back motor causing a rotation of the back in relation to the seat. This is achieved using a relatively simple linkage, where each motor is independently operable. And, due to an improved positioning of the pivot point for the seat in relation to the pivot point of the ottoman motor; and positioning of the pivot point of the seat in relation to the pivot point of the back rotation motor, the independent operation of each of the motors is achieved without the need for any special, coordinated programming of the motors. The simplified linkage also provides a lightweight mechanism usable on a variety of standard recliner styling.
Aspects herein are directed to a recliner mechanism for a seating unit, comprising a base, a base bracket coupled to the base, the base bracket having a seat pitch pivot point, a seat plate pivotally coupled to the base bracket at the seat pitch pivot point, and a seat pitch motor operably coupled between the base and the seat plate, the seat pitch motor operable to rotate the seat plate with respect to the base bracket about the seat pitch pivot point. The recliner mechanism further comprises an ottoman linkage coupled to the base an ottoman motor pivotally coupled to the seat plate at an ottoman motor pivot point, the ottoman motor operably coupled between the seat plate and the ottoman linkage, wherein the seat pitch pivot point is in close proximity to the ottoman motor pivot point, allowing independent operation of the ottoman motor and the seat pitch motor.
Additional aspects are directed to a recliner mechanism for a seating unit, comprising a base, a base bracket coupled to the base, the base bracket having a seat pitch pivot point, a seat plate pivotally coupled to the base bracket at the seat pitch pivot point, a seat pitch motor operably coupled between the base and the seat plate. The recliner mechanism further comprises an ottoman linkage coupled to the seat plate, an ottoman motor pivotally coupled to the seat plate at an ottoman motor pivot point, wherein a location of the seat pitch motor pivot point and the location of the ottoman motor pivot point allows for independent operation of the ottoman motor and the seat pitch motor.
Further aspects are directed to a recliner mechanism for a seating unit, comprising a base having a pair of spaced apart base rails and a pair of cross-tubes, a base bracket coupled to the base, a seat plate pivotally coupled to the base bracket at a seat pitch pivot point, a seat pitch motor operably coupled to rotate the seat plate with respect to the base bracket about the seat pitch pivot point. The recliner mechanism further comprises an ottoman linkage coupled to the seat plate, an ottoman motor operably coupled between the seat plate and the ottoman linkage, wherein the ottoman motor and the seat pitch motor are independently operable from one another.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments of the invention are described in detail below with reference to the attached drawing figures, and wherein:
FIG. 1 depicts a side view of a mechanism in the closed position, in accordance with aspects hereof;
FIG. 1A depicts a view similar to FIG. 1, with selected parts hidden to reveal certain pivot points;
FIG. 1B depicts a simplified view of part of FIG. 1 (from the other side, and with many parts hidden and other parts repeated in different orientations), revealing the relative position of certain pivot points;
FIG. 1C is a side, cross section view taken along line 1C-1C in FIG. 2;
FIG. 2 depicts a perspective view of the mechanism of FIG. 1, in accordance with aspects hereof;
FIG. 3 depicts a side view of the mechanism of FIG. 1 in a TV position, with the ottoman extended, in accordance with aspects hereof;
FIG. 4 depicts a perspective view of the mechanism of FIG. 3, in accordance with aspects hereof;
FIG. 5 is a view similar to FIG. 4, but with the seat pitch adjusted, in accordance with aspects hereof;
FIG. 6 depicts a perspective view of the mechanism of FIG. 5, in accordance with aspects hereof;
FIG. 7 is similar to FIG. 5, but shown with the back reclined, in accordance with aspects hereof;
FIG. 8 depicts a perspective view of the mechanism of FIG. 7, in accordance with aspects hereof;
FIG. 9 depicts a side view of the mechanism in a “zero-gravity” position, with the back partially reclined, the seat pitch partially adjusted and the ottoman partially extended, in accordance with aspects hereof;
FIG. 10 depicts a perspective view of the mechanism of FIG. 9, in accordance with aspects hereof;
FIG. 11 is similar to FIG. 10, but shown from a different perspective, in accordance with aspects hereof;
FIG. 12 depicts top plan view of the mechanism of FIG. 9, in accordance with aspects hereof;
FIG. 13 depicts a perspective view of a different aspect of a mechanism, showing a modified back linkage, in accordance with aspects herein;
FIG. 14 depicts a perspective view of the mechanism of FIG. 13, shown with the ottoman extended and the back reclined; and
FIG. 15 depicts a perspective view of the mechanism of FIG. 13, shown with the seat tilted, the back reclined and the ottoman extended.
DETAILED DESCRIPTION
The subject matter of embodiments of the invention is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps, components, or combinations thereof, in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Referring to the drawings, FIGS. 1-2 show a recliner mechanism 10 in the closed position with a back bracket 12 substantially upright, a seat rail 14 in a relatively horizontal position (with a slight pitch in the seat from back to front) and an ottoman linkage 16 in a closed position, FIGS. 3-4 show the mechanism 10 in the TV position, with the ottoman linkage 16 extended; FIGS. 5-6 show the recliner mechanism 10 in the TV position, but with the pitch of the seat rail 14 adjusted with more of an incline from back to front; FIGS. 7-8 show the recliner mechanism 10 in a position similar to FIGS. 4-5, but with the back bracket 12 fully reclined, and FIGS. 9-12 show the mechanism 10 in a “zero-gravity” position, with the back bracket 12 partially reclined, the pitch of the seat rail 14 partially adjusted, and the ottoman linkage 16 partially extended. While these various positions are shown for purposes of this description, it should be understood after reading the disclosure below that each of the rotation of the back bracket 12, the pitch of the seat rail 14 and the extension of the ottoman linkage 16 are independently adjustable to provide an wide variety of possible positions for the user of the chair on which the mechanism 10 is installed.
Referring initially to FIGS. 1-2, the mechanism 10 is shown that couples together a chair back (mounted on back bracket 12), a chair seat (mounted on seat rail 14) and an ottoman (mounted on the ottoman linkage 16) of a recliner. One of skill in the art would understand the attachment of these chair components to the mechanism 10. For the sake of clarity, these portions of the chair are not shown.
As seen in FIG. 2, the mechanism 10 includes a pair of spaced apart base rails 18 coupled together with a pair of cross-tubes 20. In some aspects, the base rails 18 may include an outwardly bent rear end to provide additional support for the remainder of the mechanism 10 (forming a somewhat J shape). The cross-tubes 20 may, in some aspects, be welded to the base rails 18. In some aspects, the mechanism 10 may also include feet 22 to support the base rails 18 above a surface on which mechanism 10 rests. As seen in FIG. 1, a base bracket 24 is fixedly coupled to each base rail 18, such as by bolting, riveting or welding. The base bracket 24 is generally in the shape of a parallelogram with sides angled toward the rear of the mechanism 10 and with a general horizontal top and bottom (although other shapes could be used). For additional support, in some aspects, a brace 26 may be welded or otherwise affixed between the base rail 18 and the upper, rear end of the base bracket 24. An attachment bracket 28 is also fixedly coupled to the base bracket 24. Throughout this disclosure, components that are described as fixedly coupled to one another could be affixed in any of a number of ways, including, but not limited to, rivets, bolts, and weldments. In some aspects, the attachment bracket 28 and the base bracket 24 could be formed as a unitary piece. As seen in FIG. 2, the attachment bracket 28 extends upwardly from the top of the base bracket 24. A rear ottoman cross-tube 30 is fixedly coupled to the upper end of each attachment bracket 28, with the rear ottoman cross-tube 30 extending between the attachment brackets 28. A motor bracket 32 is fixedly coupled to the cross-tube 30, generally midway along the cross-tube 30. The lower end of the motor bracket 32 is pivotally coupled to an ottoman motor 34 at pivot point 36. Through the base bracket 24, the attachment bracket 28, the rear ottoman cross-tube 30 and the motor bracket 32, the pivot point 36 is strategically located, as is discussed further below.
As seen in FIGS. 1A and 11, the extending shaft of the ottoman motor 34 is pivotally coupled to a motor bracket 38 at a pivot point 40. The motor bracket 38 is fixedly coupled to an ottoman drive tube 42. The ottoman drive tube 42 extends between, and is fixedly coupled to, the ottoman linkage 16. More specifically, the ottoman drive tube 42 is fixedly coupled to a pair of front motor tube links 44 (as best seen in FIG. 1C). The front motor tube link 44 is somewhat L-shaped, with the shorter forward end coupled to the ottoman drive tube 42. The front motor tube link extends rearwardly (as viewed in FIG. 1C) and is pivotally coupled on the outer end to a rear ottoman link 46 at pivot point 48. As seen in FIG. 1, the upper end of the rear ottoman link 46 is pivotally coupled to a seat plate 50 at pivot point 52. As seen in FIGS. 9 and 10, the end of the rear ottoman link 46 opposite pivot point 52 is pivotally coupled to a main ottoman link 54 at pivot point 56. The main ottoman link 54 extends away from pivot point 56 and is pivotally coupled at the other end to an ottoman bracket 58 at pivot point 60. The ottoman bracket 58 supports the main ottoman of the chair. The ottoman bracket 58 is also pivotally coupled to an outside ottoman link 62 at pivot point 64. The outside ottoman link 62 extends from pivot point 64 and is pivotally coupled at the other end to a front ottoman link 66 at pivot point 68. As seen in FIG. 10, a mid-ottoman bracket 70 is also pivotally coupled to the outside ottoman link 62 at pivot point 72. The mid-ottoman bracket 70 is also pivotally coupled to the main ottoman link 54 at pivot point 74. The mid-ottoman bracket 70 supports a mid-ottoman of the chair. Returning to FIG. 9, the end of the front ottoman link 66 opposite pivot point 68 is pivotally coupled to the seat plate 50 at pivot point 76. As seen in FIGS. 1C and 9, an ottoman control link 78 is pivotally coupled on one end to the front ottoman link 66 at pivot point 80 and is pivotally coupled on the other end to the front motor tube link 44 at pivot point 82. As seen in FIGS. 9 and 10, the main ottoman link 54 is also pivotally coupled to the front ottoman link 66 at pivot point 77.
The ottoman motor 34 can be operated to move the ottoman drive tube 42, which will, in turn, extend and retract the ottoman linkage 16. In some aspects, with the shaft of the ottoman motor 34 fully retracted, the ottoman linkage 16 is in the stowed position of FIG. 1. As the ottoman motor 34 extends the shaft, the ottoman drive tube 42 extends the ottoman linkage 16. With the shaft of the ottoman motor 34 fully extended, the ottoman linkage 16 is extended to the position of FIG. 3 for example. The ottoman motor 34 can be stopped at any point between these two positions, according to the desires of the user. Moreover, the ottoman linkage 16 can be independently operated, no matter the position of the back bracket 12 and the pitch of the seat rail 14 and seat plate 50.
The seat plate 50 is pivotally attached to the attachment bracket 28. More specifically, as seen in FIGS. 1 and 2, pivot bracket 84 is fixedly coupled to the seat plate 50. The pivot bracket 84 extends downwardly from the seat plate 50 and is pivotally coupled to an outwardly extending flange 86 of the attachment bracket 28 at a pivot point 88. As discussed more fully below, the pivot point 88 is in close alignment with pivot point 36. The seat rail 14 is fixedly attached to the seat plate 50, such that the seat rail 14 (and thus the seat plate 50) carry the seat of the chair. The seat rail 14 may, in some aspects, be first coupled to the seat of the chair, and thereafter coupled to the seat plate 50. Further, the orientation of the seat rail 14 with respect to the seat plate 50 may be selected (via different mounting holes on the seat plate 50) by the chair manufacturer to best suit the needs of their customers. The rearward end of the seat plate 50 is pivotally coupled to the back bracket 12 at pivot point 90. As seen in FIG. 2, near the forward end of the seat plate 50, but rearward of pivot point 52, a pitch tube 92 is fixedly coupled to, and extends between, opposing seat plates 50. Nearer to one of the seat plates 50 than the other, a motor bracket 94 is fixedly coupled to the pitch tube 92. The motor bracket 94 is used to pivotally couple the shaft of a seat pitch motor 96 at a pivot point 98. The lower end of the seat pitch motor 96 is pivotally coupled to a pitch motor bracket 100 at pivot point 102. The pitch motor bracket 100 is fixedly coupled to the front cross-tube 20, as seen in FIG. 2. The seat pitch motor 96 may be operated to rotate the seat plate 50 about pivot point 88 to change the pitch of the seat plate 50 with respect to the base rails 18. As one example, the seat pitch motor 96 can be activated to extend the shaft of the seat pitch motor 96 creating a counter-clockwise rotation (from the viewpoint of FIG. 3) of the seat plate 50 about pivot point 88. From the position of FIG. 3, full activation of the seat pitch motor 96 changes the seat pitch to the angle shown in FIG. 5. Like the independent extension and retraction of the ottoman linkage 16, the seat pitch angle may be changed no matter the position of the back bracket 12 or the ottoman linkage 16, allowing the user to select a seat pitch that is most comfortable for them. As seen in FIGS. 1C and 9, a stop bracket 104 may be fixedly coupled to the base bracket 24. The stop bracket 104 has an upper end 106 that supports the pitch tube 92 with the seat pitch motor 96 and the pitch tube 92 in the lowered position (of FIG. 3, for example).
As set out above, the back bracket 12 is pivotally coupled to the seat plate 50 at pivot point 90. The back bracket 12 has an upper end that is used to couple the back bracket 12 to the back of the chair. As seen in FIG. 3, a drive control bracket 108 is fixedly coupled to the back bracket 12. In some aspects, the drive control bracket 108 can be integrally formed with the back bracket 12. The drive control bracket 108 extends downwardly from the back bracket 12. As seen in FIG. 4, a recline tube 110 is fixedly coupled to, and extends between, the drive control brackets 108. The recline tube 110 has a rear motor bracket 112 fixedly coupled thereto, as seen in FIGS. 1 and 1B. The rear motor bracket 112 is pivotally coupled to the shaft of a recline motor 114 at pivot point 116. As seen in FIGS. 1A and 10, the opposite end of the recline motor 114 is pivotally coupled to a motor bracket 118 at pivot point 120. The motor bracket 118 is fixedly coupled to the front cross-tube 20 (see FIG. 10).
The recline motor 114 may be engaged to extend and retract the shaft of the recline motor 114. As the shaft of the recline motor 114 retracts, the recline angle of the back bracket 12 increases. For example, by retracting the shaft of the recline motor 114, the mechanism 10 can be moved from the position in FIG. 5 to the position in FIG. 7. Like the independent operation of the ottoman motor 34 (and ottoman linkage 16) and the independent operation of the seat pitch motor 96 (to alter the pitch of seat plate 50), the recline motor 114 is operable independently to allow a user to change the recline angle of the back bracket 12 (and thus the back of the chair) at any time. So, for example, the ottoman linkage 16 could be extended by ottoman motor 34, and the shaft of the recline motor 114 could be retracted to recline the back bracket 12.
The independent operation of the ottoman motor 34 and the seat pitch motor 96 is allowed, at least in part, due to the geometry of the mechanism 10, and the positioning of relevant pivot points. More specifically, as seen in FIG. 1B, pivot point 36 is in close proximity to pivot point 88. As seen in FIG. 1B, pivot point 36 is slightly behind, and below, pivot point 88. In some aspects, pivot point 36 could be positioned directly on top of pivot point 88. It has been found, however, that having the pivot point 36 slightly behind and below pivot point 88 allows the ottoman motor 34 to have sufficient room, or stroke, to fully extend the ottoman linkage 16. By positioning pivot point 36 in close proximity to pivot point 88, as the seat pitch changes (through operation of the seat pitch motor 96) the arc formed by a radius extending from pivot point 36 to pivot point 40 very closely follows the arc formed by a radius extending from pivot point 88 to pivot point 40. This allows the seat pitch motor 96 to operate, without having an effect on the ottoman linkage 16. Were pivot points 36 and 88 not closely aligned, operation of the seat pitch motor 96 might bind, or bend, the links within the ottoman linkage 16, or put undue stress on the seat pitch motor 96.
Somewhat similarly, an arc formed by a radius extending from pivot point 120 to pivot point 116 closely follows an arc formed by a radius extending between pivot point 88 and pivot point 116. This allows the seat pitch motor 96 to operate, without having a significant effect on the recline of the back bracket 12. This allows the independent operation of the seat pitch motor 96 and the recline motor 114, without negatively affecting the coupling of the back bracket 12 and the seat plate 50.
Using the above-described mechanism 10, having the geometry and pivot point positioning as described, a recliner mechanism is provided with three independently operable motors, each effecting an independent movement of a portion of a chair. This is achieved using a relatively simple linkage, where each motor is independently operable. And, due to an improved positioning of the pivot point for the seat in relation to the pivot point of the ottoman motor; and positioning of the pivot point of the seat in relation to the pivot point of the back rotation motor, the independent operation of each of the motors is achieved without the need for any special, coordinated programming of the motors. The simplified linkage also provides a lightweight mechanism usable on a variety of standard recliner styling, while allowing an almost infinitely customizable positioning to suit the individual preferences of a user seated in a chair using mechanism 10.
Another aspect is shown in FIGS. 13-15 having a modified back linkage. Many of the components remain the same as those discussed above with respect to FIGS. 1-12, and are not further discussed with respect to FIGS. 13-15. A mechanism 250 is shown in FIGS. 13-15 that indirectly couples the back bracket 12 to a slightly modified seat plate 50A. More specifically, the back bracket 12 is pivotally coupled to a back pivot link 200 at a pivot point 202. The opposite end of the back pivot link 200 is pivotally coupled to the seat plate 50A at a pivot point 204. The back bracket 12 is also pivotally coupled to a back control link 206 at a pivot point 210. The back control link 206 is pivotally coupled to the seat plate 50A at a pivot point 208. A support wheel 212 is coupled to the lower end of the back control link 206 via a bracket 216. In some aspects, the support wheel 212 is also supported via a bracket 218 fixedly coupled to the recline motor tube 110. In other words, the support wheel 212 is rollingly supported between brackets 216 and 218. In some aspects, the mechanism 250 also includes an arced support ramp 214. The support wheel 212 contacts the ramp 214 when the pitch of the seat plate 50A is adjusted (the adjustment of the seat pitch being as described above with respect to FIGS. 1-12). With this arrangement, the back bracket 12 rotates about a projected pivot point (shown in the general area of 220 in FIG. 13). To recline the back, the operation of the recline motor 114A operates slightly differently than described above with reference to FIGS. 1-12. In the aspect shown in FIGS. 13-15, the motor 114A can extend the shaft to recline the back bracket 12 from the position shown in FIG. 13 to the reclined position shown in FIGS. 14 and 15. In this aspects, the seat pitch, the ottoman extension and the back recline can still be independently adjusted. As seen in FIG. 15, if the seat pitch is tilted, the support wheel 212 is supported by the support ramp 214 (with the back either in the upright position (with the wheel 212 at the top of the support ramp 214) or in the reclined position (with the support wheel at the lower end of the support ramp 214).
Many different arrangements of the various components depicted, as well as components not shown, are possible. Embodiments of the technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments 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 subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.
Patent Application
20240365979
