Hidden footrest recliner mechanism with high-leg design

Abstract

The present invention relates to a seating unit that is movable between a folded position, an extended position, and a fully reclined position. The seating unit comprises two side portions spaced apart from each other and a seat portion extending between the two side portions, an extendable footrest, and a seat back extending upward from a rear edge of the seat portion. The seating unit further comprises a side panel adjacent to a corresponding one of the two side portions and at least one support tube extending between the side panels. The seating unit has a linkage mechanism supported on the side panels, the linkage mechanism coupling at least the footrest and the seat back. A motor is coupled to the linkage mechanism to move the seating unit between the folded position, the extended position, and the fully reclined position, wherein the motor extends above the at least one support tube.

Description

Technical Field

[0001] Embodiments of the present invention relate to a recliner mechanism and a chair using the same, and more particularly to an electric / powered recliner mechanism for a chair having a high-leg design, and a footrest and motor that are hidden from view when in a storage position. Background Art

[0002] One type of chair design that utilizes a reclining mechanism is known as a high-leg design. In these types of chairs, legs suspend the seat above the floor surface, allowing a view underneath. In chairs with this design, the footrest is stored in a more horizontal position (compared to a vertical position). Until now, it has been difficult to provide a motorized mechanism to extend the footrest and tilt / recline a chair with this design. One challenge in providing a powered reclining mechanism for use with this style of chair is the positioning of the motor. To maintain the high-leg chair's aesthetic, the motor powering the mechanism must be invisible, or at least unobtrusive and largely invisible. The motor must be positioned and coupled to the rest of the linkage mechanism so that the footrest moves from a stowed position approximately 67 degrees above vertical (relative to the floor), through a vertical position, to an extended position substantially parallel to the floor. Therefore, the motor must be positioned high enough to be relatively invisible, yet also fit within the rest of the mechanism and not interfere with any linkages or any parts of the seat unit, such as the seat springs supporting the seat. Summary of the Invention

[0003] A seating unit is provided that moves between a stowed position, an extended position, and a fully reclined / fully reclined position. The seating unit includes two side portions spaced apart from one another and a seat extending between the two side portions, an extendable footrest, and a seat back extending upward from a rear edge of the seat portion. The seating unit also includes side panels adjacent a respective one of the two side portions and at least one support tube extending between the side panels. The seating unit has a linkage supported on the side panels, the linkage coupling at least the footrest and the seat back. A motor is coupled to the linkage to move the seating unit between the stowed position, the extended position, and the fully reclined position, wherein the motor extends above the at least one support tube. In some aspects, the side portions of the seat have a bottom edge spaced apart from a support surface on which the seating unit rests when in use, wherein the side portions of the seat substantially obscure the linkage and the motor from view.

[0004] In some aspects, in the extended position, the linkage mechanism maintains the footrest substantially parallel to the support surface on which the seat unit rests, and when the motor moves the linkage mechanism from the extended position to the retracted position, the linkage mechanism moves the footrest past a position perpendicular to the support surface on which the seat unit rests, to a position at least approximately 45 degrees beyond perpendicular to the support surface on which the seat unit rests, or to a position at least approximately 55 degrees beyond perpendicular to the support surface on which the seat unit rests, or to a position at least approximately 67 degrees beyond perpendicular to the support surface on which the seat unit rests.

[0005] In some aspects, the seat includes a padded portion supported on an elastic support surface of the seating unit, and the elastic support surface has a maximum deformation position in which the motor is spaced at least 1.5 inches, or at least 2 inches, or at least 2.5 inches from the elastic support surface.

[0006] In some aspects, at least one support tube includes a downwardly extending central section that provides clearance for the motor above the at least one support tube.

[0007] Other purposes, advantages and novel features of the present invention will be set forth in part in the following description and in part will become apparent to those skilled in the art after studying the following contents or may be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will be described in detail below with reference to the accompanying drawings, in which:

[0009] Figure 1 is a cross-sectional view of an exemplary chair according to an embodiment of the present invention, wherein the mechanism is in a stowed position, illustrating one side of the mechanism;

[0010] Figure 2 is similar to Figure 1 , but showing the seat in the TV position or extended position;

[0011] Figure 3 is similar to Figure 2 , but showing the seat in the fully reclined position;

[0012] Figure 4 is similar to Figure 1 , but showing the seat transitioning from the stowed position to the TV position;

[0013] Figure 4A is in Figure 1 views of selected parts of the mechanism in position;

[0014] Figure 4B is in Figure 1 views of selected parts of the mechanism in position;

[0015] Figure 4C is in Figure 1 views of selected parts of the mechanism in position;

[0016] Figure 5 It is in the TV position Figure 2 a view of the mechanism showing selected components exploded;

[0017] Figure 6 is in a fully reclined position Figure 3 a view of the mechanism showing selected components exploded;

[0018] Figure 7 is similar to Figure 1 ' view showing additional decorative trim;

[0019] Figure 8 yes Figure 7 A side view of a seat;

[0020] Figure 9 yes Figure 7 Front view of the seat;

[0021] Figure 10 is in Figure 1 views of selected components shown in a stowed position;

[0022] Figure 11 is in Figure 2 a view of the selected component of the TV location; and

[0023] Figure 12 is in Figure 3 View of the selected component in the fully tilted position. DETAILED DESCRIPTION

[0024] Embodiments of the present invention are generally directed to a seating unit having a motor mechanism / motorized mechanism that can be used inconspicuously in a high-leg type chair, which moves a footrest from a stowed position to an extended position and can tilt the backrest / back of the seating unit when the footrest is extended.

[0025] exist Figure 1 An exemplary seating mechanism 10 is shown in cross-section in FIG. 1 , showing a seating unit 12 in a stowed position. In some aspects, the seating unit 12 has legs 14, side frames 16 that cooperate with the mechanism 10 to support a seat 18 above a floor or other support surface. The seating unit 12 also has armrests 20 that, in some embodiments, are integrally formed with the legs 14. The mechanism 10 allows the seating unit 12 to have a so-called "high leg" configuration, while allowing the seating unit 12 to have a configuration that is positioned so that the seating unit 12 is Figure 1The folded position, Figure 2 The extended position (or TV position) and Figure 3 The motor moves the cam between the fully tilted position and the Figure 2 In the extended position, the back 22 remains in a generally vertical position, but the footrest assembly 24 enables the footrest 25 to be adjusted from the upright position to the upright position. Figure 1 Move to the stowed position shown as Figure 2 shown in the extended position. Figure 2 In the extended position, the seat 18 moves rearward, and the seat 18 tilts from the rear of the seat 18 to the front of the seat 18. Figure 3 In the fully reclined position, the back portion 22 is tilted relative to the seat portion 18, the footrest assembly 24 remains extended, and the seat portion 18 moves further rearward, increasing the recline angle of the seat portion 18.

[0026] For simplicity, the mechanism 10 is Figures 4A-4C to Figure 6 The armrest 13 is shown without the rest of the seat unit 12. The mechanism 10 is coupled to the seat unit 12 via the armrest mount 13, as shown in FIG. Figure 6 As best shown, the armrest chassis 13 includes side panels 15 fixedly coupled to respective side frames 16. A front support tube 17 and a rear support tube 19 are fixedly coupled between the opposing side panels 15 such that the front support tube 17 and the rear support tube 19 extend from one side of the seating unit 12 to the other. In some aspects, the front support tube 17 is straight from one end to the other. In some aspects, the rear support tube 19 includes a downwardly curved central portion 21 to provide clearance for other components, as described below.

[0027] The base link 26 is fixedly coupled to the armrest base 13, for example by bolting a flange 27 on the base link 26 to the front support tube 17 and the rear support tube 19. The front lower end of the base link 26 has a spring connection point 28. The spring connection point 28 can be simply a hole in the base link 26, or it can be a pin that secures the spring 30, such as Figure 4C As shown. The spring 30 moves the mechanism 10 toward Figure 1 The spring 30 is shown in only some of the figures to avoid obscuring the other links. The chassis link 26 also has an elongated slot 34 formed therein, the function of which will be described further below. Forward of the slot 34, a pin 32 is fixedly coupled to the chassis link 26 and extends outwardly therefrom. When in the stowed position, the pin 32 supports the other components of the mechanism 10.

[0028] The rear tilt link 36 is pivotally coupled to the second end of the chassis link 26 at a pivot point 38. The pivot point 38 is shown in solid lines in the figure to provide a reference, although it is visually obscured by the other links. The rear tilt link 36 is shaped as shown in FIG. Figure 6The pivotal movement of the recline link 36 relative to the base link 26 is controlled and constrained by a rivet 40 (or other connector) that couples the recline link 36 to the base link 26 at the slot 34. The rivet 40 allows the recline link 36 to rotate about the pivot point 38 from a lower position (where the rivet 40 is located at the bottom of the slot 34 when the mechanism 10 is in the stowed and extended positions) to a fully reclined position (where the rivet 40 is located at the bottom of the slot 34 when the mechanism 10 is in the stowed and extended positions). Figure 6 ) and the rivet 40 is at the top of the slot 34 - the raised position. In the lowered position, the rear tilt link 36 is also supported by the pin 32 on the chassis link 26.

[0029] Below the pivot point 38, the back pivot link 42 is pivotally coupled to the recline tilt link 36 at a pivot point 44. The back pivot link 42 extends upward from the pivot point 44 and is pivotally coupled at its other end to the back link 46 at a pivot point 48. The back pivot link 42 has a retaining finger 50 that extends upward beyond the pivot point 48, as shown in FIG. Figure 5 When the organization is in Figure 4 The folded position and Figure 6 When the backrest 22 is in the fully tilted position, the finger 50 is retained to engage a stop post 52, which is fixedly coupled to and extends from the back link 46 to provide additional stability. As known to those skilled in the art, the back link 46 has a generally triangular shape and is used to couple the back 22 to the mechanism 10.

[0030] 6. The seat link 54 is pivotally coupled to the front lower end of the back link 46 at a pivot point 56. The seat link 54 carries and supports the seat 18. Below the pivot point 56, a rear pivot link 58 is pivotally coupled to the seat link 54 at a pivot point 60. The rear pivot link 58 extends away from the pivot point 60, has a slight bend in the middle, and is pivotally coupled to the recline pivot link 62 at a pivot point 64. The recline pivot link 62 is also pivotally coupled to the recline tilt link 36 at a pivot point 66 near the midpoint of the recline pivot link 62. At this midpoint, the recline pivot link 62 has a slight bend. The end of the recline pivot link 62 opposite the pivot point 64 has a slot 68 for connecting the recline pivot link 62 to the base frame link 26 via a rivet 70. As shown by comparison Figure 4 and Figure 6 As best seen, the slot connection provided by slot 68 and rivet 70 allows tilt pivot link 62 to pivot about pivot point 66 .

[0031] Near rivet 40, one end of the footrest drive link 72 is pivotally coupled to the rear tilt link 36 at pivot point 74. Retained with the rear tilt link 36, a front pivot link 76 is pivotally coupled to the front end of the rear tilt link 36 at pivot point 78. The upper end of the front pivot link 76 has a spring connection 82. Like the spring connection 28, the spring connection 82 can simply be a hole in the front pivot link 76, or it can be a post extending from the front pivot link 76. Figure 4C As best shown, spring 30 is coupled to and located between front pivot link 76 and chassis link 26 at spring connection 82 and spring connection 28 , respectively, to bias mechanism 10 toward the stowed position.

[0032] The end of the footrest drive link 72 opposite the pivot point 74 is pivotally coupled to a lower footrest link 84 located approximately in the middle of the lower footrest link 84 at a pivot point 86. The footrest drive link 72 is shaped as shown in FIG. Figure 6 8 and is pivotally coupled to the recline link 36 and the lower footrest link 84. The upper end of the lower footrest link 84 is pivotally coupled to the seat link 54 at a pivot point 88. The lower end of the lower footrest link 84 is pivotally coupled to the main footrest link 90 at a pivot point 92. The end of the main footrest link 90 opposite the pivot point 92 is pivotally coupled to the footrest bracket 94 at a pivot point 96. An upper footrest link 98 of the footrest assembly 24 is pivotally coupled to the main footrest link 90 at a pivot point 100. A first end 102 of the upper footrest link 98 is pivotally coupled to the seat link 54 at the pivot point 102. The footrest assembly 24 also includes a second footrest link 104 that is pivotally coupled to the upper footrest link 98 at a pivot point 106. The end of the second footrest link 104 opposite the pivot point 106 is pivotally coupled to the footrest bracket 94 at a pivot point 108. In some aspects, the middle footrest bracket 110 is also pivotally coupled to the second footrest link 104 via a linkage.

[0033] like Figure 6 As best shown in FIG, the top of the front pivot link 76 is pivotally coupled to the seat link 54 at pivot point 112. The bottom of the front pivot link 76 is pivotally coupled to the drive link 114 at pivot point 116. The other end of the drive link 114 is pivotally coupled to the connector link 118 at pivot point 120. When the drive link 114 extends from pivot point 116 to pivot point 120, it has a central flat portion 117. In the stowed position, the pivot points 116 and 120 are above the bottom of the central flat portion 117. The connector link 118 is also pivotally coupled to the chassis link 26 at pivot point 122, as shown in FIG. Figure 61. The connector link 118 is fixedly coupled to the front motor tube 124 via end brackets 126, such as by placing bolts or other connectors through holes 128. The front motor tube 124 extends between the opposing brackets 126. In the approximate middle of the front motor tube 124, a clevis / wedge bracket 130 is used to pivotally couple the front motor tube 124 to the shaft of a motor 132. The rear of the motor 132 is pivotally coupled to the rear motor tube 134 via a wedge bracket 136 at pivot point 138. Each end of the rear motor tube 134 is coupled to a respective chassis link 26, such as Figure 4C In some aspects, the torque / torque link 140 is fixedly coupled between the rear motor tube 134 and the chassis link 26 as a reinforcement. Figure 4A 、 Figure 4B 、 Figure 5 and Figure 6 In FIG. 1 , certain components connecting the motor 132 to the rest of the mechanism 10 are shown broken away below the rest of the drawing to more clearly illustrate the orientation and movement of those components.

[0034] In order to make the mechanism 10 and the seat unit 12 Figure 1 The collapsed position is converted to Figure 2 To return the seat to the extended position, the user will activate the motor 132, which causes the shaft of the motor 132 to retract. This force pulls the fork bracket 130 rearward and causes the front motor tube 124 to rotate. Due to the fixed connection between the front motor tube 124 and the connector link 118, the rotation of the front motor tube 124 also causes the connector link 118 to rotate about the pivot point 122. As the connector link 118 rotates, it moves the drive link 114, thereby also causing the front pivot link 76 to rotate about the pivot point 78 and the pivot point 112. This rotation drives the seat link 54 upward and rearward. As the seat link 54 moves upward and rearward, the footrest drive link 72 causes the footrest assembly 24 to move to the rear. Figure 2 In addition, as the seat link 54 moves upward and rearward, the rear pivot link 58 and the back pivot link 42 act on the back link 46 to rotate it to a slightly tilted position. In the stowed position, the footrest 25 is angled relative to the floor. In some aspects, the angle is at least 45 degrees above vertical. In other aspects, the angle is at least 55 degrees above vertical. In still other aspects, Figure 1 and Figure 7 As shown, the angle exceeds the vertical position by at least 67 degrees. When moving to the TV position, the footrest 25 moves through a position perpendicular to the floor (such as Figure 4 ), and moved out to a position roughly parallel to the floor in the TV position. When the footrest 25 is in the angled stowed position, the footrest 25 is visually hidden.

[0035] In addition, if Figure 10-12As best shown in the figures, the motor 132 is mounted to the rear motor tube 134 and the front motor tube 124 in an angled position / tilt such that the rear portion of the motor 132 is lower than the front fork support 130 that mounts the shaft of the motor 132 to the front motor tube 124. In this angled position, the motor 132 is positioned above the center bend 21 of the rear support tube. Furthermore, due to this unique mounting, the motor 132 and the mechanism 10 are substantially obscured or hidden from view, which may be desirable for at least some users. As used herein, the term "substantially" when used herein to describe the portion of the motor that is visible includes a range of 80% to 100%. For example, the motor 132 is substantially obscured from view when at least about 80% of the motor is obscured from view. In other aspects, well over 80% of the motor is obscured from view, such as Figure 8 and Figure 9 . The front pivot link 76, the drive link 114 and the connector link 118 form a compact linkage between the motor 132 and the rest of the mechanism 10, allowing the motor 132 to provide motorized opening and closing of the mechanism while remaining essentially invisible. Because the connector link 118 has a bend at the center portion 117, when in Figure 1 In the stowed position, the connector link 118 is visually hidden. Although the motor 132 is mounted high enough to be visually hidden, the motor 132 is also mounted low enough to provide clearance for the seat 18. More specifically, as Figure 10-12 As shown, the motor 132 is mounted below a support spring / support member 150 that provides cushioning and support for the remainder of the seat 18. In some aspects, a maximum deflection position of the spring 150 can be determined, such as at a position depicted by dimension / range 152. In some aspects, at the maximum deflection position 152, the motor 132 has at least 1.5 inches of clearance in each position of the seat 12, or at least 2 inches of clearance in each position of the seat 12, or at least 2.5 inches of clearance in each position of the seat 12.

[0036] In order to make the mechanism 10 and the seat 12 Figure 2 The TV position moves to Figure 3 To achieve the fully reclined position, the user can further activate motor 132 to further retract the shaft of motor 132. This movement causes the rear tilt link 36 to pivot relative to the chassis link 26 about pivot point 38. During this movement, the rear tilt link 36 is guided and restrained by rivet 40 in slot 34. As the rear tilt link 36 pivots, rivet 40 moves from the bottom of slot 34 to the top of slot 34. As the rear tilt link 36 pivots about pivot point 38, pivot point 44 is pulled forward, further tilting the back link 46 (and back 22).

[0037] From the foregoing, it will be apparent that the present invention is well adapted to achieve all of the objects and goals set forth above, as well as other advantages, which are inherent and apparent to this configuration. It will be understood that certain features and subcombinations are useful and can be employed without involving other features and subcombinations. This is contemplated by and within the scope of the claims. Because many possible embodiments of the present invention can be made without departing from the scope of the invention, it will be understood that all matter set forth herein or shown in the accompanying drawings is to be interpreted as illustrative and not restrictive.

Claims

1. A seating unit movable between a stowed position, an extended position and a fully reclined position, the seating unit comprising: two side portions spaced apart from each other; a seat portion extending between the two side portions; an extendable footstool; a chair back extending upward from a rear edge of the seat; a side panel adjacent to each of the two side portions; at least one support tube extending between the side panels; A linkage mechanism supported between the side panels and connecting at least the footrest and the seat back; and a motor coupled to the linkage mechanism to move the seating unit between the stowed position, the extended position, and the fully reclined position, wherein the motor extends above the at least one support tube, wherein the at least one support tube comprises a downwardly extending central section which provides clearance for the motor above the at least one support tube, wherein the side portion of the seat has a bottom edge spaced from a support surface on which the seating unit rests when in use, and Therein, the sides of the seat substantially shield the linkage mechanism and the motor from view.

2. The seating unit of claim 1, wherein: In the extended position, the linkage mechanism maintains the footrest substantially parallel to the support surface on which the seat unit rests, and when the motor moves the linkage mechanism from the extended position to the stowed position, the linkage mechanism moves the footrest through a position perpendicular to the support surface on which the seat unit rests to a position at least 45 degrees beyond perpendicular to the support surface on which the seat unit rests.

3. The seating unit of claim 2, wherein: When the motor moves the linkage mechanism from the extended position to the stowed position, the linkage mechanism moves the footrest through a position perpendicular to the support surface on which the seating unit rests to a position at least 55 degrees beyond perpendicular to the support surface on which the seating unit rests.

4. The seating unit of claim 3, wherein: When the motor moves the linkage mechanism from the extended position to the stowed position, the linkage mechanism moves the footrest through a position perpendicular to the support surface on which the seating unit rests to a position at least 67 degrees beyond perpendicular to the support surface on which the seating unit rests.

5. The seating unit of claim 1, wherein: The seat includes a cushion portion supported on a resilient support surface of the seating unit, the resilient support surface having a maximum deformation position, in which the motor is spaced at least 1.5 inches from the resilient support surface.

6. The seating unit of claim 5, wherein: In the position of maximum deformation, the motor is spaced at least 2 inches from the resilient support surface.

7. The seating unit of claim 6, wherein: In the position of maximum deformation, the motor is spaced at least 2.5 inches from the resilient support surface.

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