Deck chair

Abstract

A reclining chair includes a frame, a first sling anchor, a second sling anchor, a sling, and a threaded fastener. The frame includes at least two side members. A first sling anchor is connected with the first side member and is movable relative to the frame. A second sling anchor is connected with the second side member. The second side member is disposed on an opposite side of the frame from the first side member. The sling is secured to the first sling anchor and the second sling anchor and spans between the first side member and the second side member. The sling defines a support surface on which an associated occupant may selectively reside. A threaded fastener engages the first sling anchor and the first side member. Rotation of the threaded fastener relative to at least one of the first sling anchor and the first side member moves the first sling anchor relative to the first side member, thereby moving the sling relative to the first side member.

Description

Background Art

[0001] A conventional recliner includes a rectangular frame with a leg at each corner. A main seat is connected to the frame for supporting the lower body of the occupant. A backrest structure is pivotally connected to the frame for supporting the upper body of the occupant in a reclined position. The backrest is typically fixed at one of several predetermined angles, and a support member assembly is connected between the backrest and the frame.

[0002] The sling used to support an occupant of a conventional outdoor recliner is typically rectangular in shape and includes an elongated hemming pocket along two opposing edges that is the same length as the sling. This hemming pocket is typically used to secure each edge of the sling to each respective side frame member of the conventional recliner. After the hemming pocket of each edge is positioned within the respective side frame member, an anchor rod is inserted into the hemming pocket from one end. The anchor rod is typically circular in cross-section and is sized to fit snugly within the hemming pocket and to be larger than the width of the slot through which the sling passes through each side frame member. When the anchor rod is properly positioned within the hemming pocket and within the side frame members, the hemming pocket will not be able to pass through the slot and therefore the sling will remain secured to the side frame members.

[0003] One problem with the prior art methods of securing the slings to the side frame members is that if the slings begin to sag or become damaged over time, there is no way to tighten or easily replace the slings. In this case, the owner's options include attempting to replace the slings, using a relatively complicated process and uncommon tools, and considering replacing the entire recliner.

[0004] Although conventional recliners typically include a sturdy frame, one problem with conventional recliner construction is that it relies on the quality of several different weld points and holes. For example, in a typical conventional recliner, the backrest support bracket is pivotally attached to a hinge point located on the back of the backrest. This hinge point is typically welded to the backrest assembly and must withstand constant strain and stress while the recliner is in use. If this weld point fails on a particular recliner at a hotel resort, for example, the hotel may discard the entire recliner. It would take too much effort and expense to disassemble the recliner, repair the broken weld, re-weld, re-spray the parts, and then reassemble the recliner. The cost of repairing a broken recliner may exceed the cost of replacing a new one. However, new recliners are expensive, and their durability and lifespan will once again be determined by the weakest weld or part. Conventional recliners are not designed to be easily repaired and are typically used for two to three years in a hotel or resort environment. Ideally, recliners can be repaired quickly, easily, and cost-effectively in the field to extend the life of the original recliner. Extending the life of a product is an effective and compelling sustainability strategy. Summary of the invention

[0005] In view of the above, a recliner includes a frame, a first sling anchor, a second sling anchor, a sling, and a threaded fastener. The frame includes at least two side members, at least one cross member connecting the at least two side members, and a plurality of legs. The first sling anchor is connected to a first side member of the at least two side members and is movable relative to the frame. The second sling anchor is connected to a second side member of the at least two side members. The second side member is disposed on an opposite side of the frame from the first side member. The sling is fixed to the first sling anchor and the second sling anchor and spans between the first side member and the second side member. The sling defines a support surface on which an associated occupant can selectively reside. The threaded fastener is engaged with the first sling anchor and the first side member. Rotation of the threaded fastener relative to at least one of the first sling anchor and the first side member causes the first sling anchor to move relative to the first side member, thereby causing the sling to move relative to the first side member.

[0006] According to another aspect, a recliner includes a primary frame, a secondary frame, an occupant support, and at least one mechanical fastener. The primary frame includes at least two primary side members connected by at least one primary cross member, and a ledge protruding inwardly from at least one of the at least two primary side members toward another of the at least two primary side members. The ledge includes at least one mounting slot extending therein. The secondary frame includes at least two secondary side members connected by at least one secondary cross member. The secondary frame is sized and shaped so that at least one of the at least two secondary side members is aligned with and supported by the ledge. An occupant support is secured to each of the at least two secondary side members and spans between the at least two secondary side members. The occupant support defines a support surface on which an associated occupant can selectively reside. At least one mechanical fastener is used to secure the secondary frame to the ledge and includes a portion extending through the at least one mounting slot in a direction parallel to a weight force exerted on the ledge by the at least one secondary side member when the at least one secondary side member is supported by the ledge. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a front perspective view of the recliner showing the backrest in a lowered position.

[0008] Figure 2 The backrest is shown in the raised position. Figure 1 Rear perspective view of a recliner.

[0009] Figure 3 The details of the main frame and the secondary frame are shown. Figure 1 A perspective composition of a lounge chair.

[0010] Figure 4 yes Figure 3 A partial perspective view of a seat part secondary side member and a seat part secondary cross member of a secondary frame is shown.

[0011] Figure 5 Yes, showing the mechanical fastener being inserted into the lower channel, Figure 3 A partial perspective view of a seat part secondary side member and a seat part secondary cross member of a secondary frame is shown.

[0012] Figure 6 yes Figure 3 A perspective composite image of the main level framework shown.

[0013] Figure 7 is used for Figure 1 A perspective composite view of the hinge assembly of the recliner is shown.

[0014] Figure 8 yes Figure 7 Another perspective composite view of the hinge assembly is shown.

[0015] Fig. 9 is an assembly detail showing the pivot mounting of the support assembly, Figure 1 A perspective view of a secondary side member of a backrest portion of a recliner.

[0016] Fig.10 yes Fig. 9 An assembled view of the pivot mount of the support assembly is shown.

[0017] Fig.11 is a detail showing the sling tensioning system in a first position, with Figure 1 A partial perspective view of the right front end of a recliner similar to the recliner shown.

[0018] Fig.12 It shows Fig.11 End views, partially cut away, of the sling tensioning system shown on either side of the recliner.

[0019] Fig.13 is a detail showing the sling tensioning system in a second position, Fig.11 A partial perspective view of the right front end of the recliner is shown.

[0020] Fig.14 is a detail of an alternative sling tensioning system shown, with Figure 1 A partial perspective view of the left front end of a recliner similar to the recliner shown.

[0021] Fig.15is a diagram showing details of a system and method for removing or installing a sling to a secondary frame, Figure 3 A partial perspective view of the secondary frame shown in FIG.

[0022] Fig.16 is a diagram showing details of the system and method during the process of removing or installing a sling, Figure 3 A partial perspective view of the secondary frame shown in FIG.

[0023] Fig.17 is shown in which each of the side members has two channels for receiving and securing two separate slings stretched between the two channels, and Figure 3 A partial cutaway perspective view of a secondary frame similar to the secondary frame shown in .

[0024] Fig.18 It has slats instead of slings as the supporting surface, and Figure 3 A partial cutaway perspective view of a secondary frame similar to the secondary frame shown in .

[0025] Fig.19 The details of the end cap are shown. Figure 3 A partial perspective view of the secondary frame shown in FIG. DETAILED DESCRIPTION

[0026] Reference Figure 1 and Figure 2 , shows an example of a recliner 10, according to one embodiment, including a main-stage frame 12 having four feet 14, two main-stage side members 16, and two main-stage cross members 18. The recliner 10 defines a front end 20 and a rear end 22, in which the occupant's feet will reside when the recliner 10 is properly used in a prone position, and a rear end 22, in which the occupant's head will rest. The recliner 10 includes a backrest 24 that rotates relative to the seat 26. As shown in FIG. Figure 3 As shown, connected to the primary frame 12 is a secondary frame 34 which includes a seat portion 36 which is connected to the primary frame 12. Figure 1 and Figure 2 The seat 26 shown in FIG. 1 is consistent with the seat 26 shown in FIG. 1 and the backrest portion 38 on the pivot connection, which is connected to the Figure 1 and Figure 2 The backrest 24 shown in FIG.

[0027] The seat portion 36 and the backrest portion 38 can be made of similar components, which can facilitate manufacturing and assembly, thereby improving efficiency and reducing costs. The secondary frame 34 includes at least two secondary side members connected by at least one secondary cross member. Figure 3In the illustrated embodiment, the secondary frame 34 includes two seat portion secondary side members 40 connected by at least one seat portion secondary cross member 42 within the seat portion 36. Each seat portion secondary side member 40 defines an inner surface 44, an open end 46, and a hinge end 48. Each seat portion secondary cross member 42 is secured to the inner surface 44 of each seat portion secondary side member 40, preferably welded thereto, such that each seat portion secondary cross member 42 is perpendicular to each parallel seat portion secondary side member 40. After connection, the seat portion secondary cross member 42 and the seat portion secondary side member 40 become an assembled rigid structure.

[0028] The back portion 38 can be assembled similarly to the seat portion 36; however, the back portion 38 is shorter in length than the seat portion 36. The secondary frame 34 includes two spaced back portion secondary side members 50 connected by at least one back portion secondary cross member 52 in the back portion 38. Each back portion secondary side member 50 defines an inner surface 54, an open end 56, and a hinge end 58. Each back portion secondary cross member 52 is secured to the inner surface 54 of each back portion secondary side member 50, preferably welded thereto, such that each back portion secondary cross member 52 is perpendicular to each parallel back portion secondary side member 50. When assembled, the back portion secondary cross members 52 and the back portion secondary side members 50 become an assembled rigid structure.

[0029] The seat portion secondary side member 40 and the back portion secondary side member 50 can have the same cross-section and can be formed by the same extrusion process. In this way, the factory can weld together long assemblies (e.g., 8 to 10 meters long, or even longer) of the secondary side members 40, 50 with appropriate secondary cross members 42, 52 (welded at predetermined locations) using appropriate fixtures, and then cut the long assemblies into certain lengths to quickly and more efficiently create separate seat portions 36 and back portions 38. The welding process can be automated to ensure speed and accuracy.

[0030] Reference Figure 3 , the main stage frame 12 also includes ledges 64 projecting inwardly from each main stage side member 16. Figure 3 Only one ledge 64 can be seen protruding inwardly from the primary side member 16, but another ledge 64 protrudes inwardly from the opposite primary side member 16 and is aligned with the primary side member 16. Figure 3 Each ledge 64 extends vertically from each respective inner surface 66 a specified distance (e.g., about 2.5 cm) and further extends from the front end 20 to the rear end 22. Each ledge 64 includes at least one mounting slot 68 extending from the upper surface 70 to the lower surface 72. A ratchet cutout 74 is also formed in each inner surface 66 of each primary side member 16, such as Figure 3 As shown, meshing teeth 76 are defined and located adjacent the rear end 22 .

[0031] In the illustrated embodiment, the seat portion secondary side member 40 and the backrest portion secondary side member 50 are both extrusions, which may be made of aluminum and have a cross-sectional profile such as Figure 4 The open end 46 of the seat portion secondary side member 40 is shown in FIG. Figure 4 and Figure 5 , to illustrate the details of the cross-sectional profile, but each back portion secondary side member 50 has the same cross-sectional profile. In this example, the seat portion secondary side member 40 includes a top surface 80, a bottom surface 82, an inner surface 44, and an outer surface 84. The cross-sectional profile of the seat portion secondary side member 40 includes a sling receiving channel, which in the embodiment of the schematic diagram is a C-shaped channel 86 having an opening 88 along the outer surface 84. Since this is a stretched profile, it is important to understand that these profile features extend the entire length of the seat portion secondary side member 40 (and the back portion secondary side member 50). The C-shaped channel 86 is used to selectively receive the side edges of the sling 90 (see Figure 1 and Figure 2 ) are anchored to the seat portion secondary side member 40 (and the back portion secondary side member 50), as described in more detail below. The sling 90 is typically made of a strong, inelastic woven fabric.

[0032] The cross-sectional profile of the seat portion secondary side member 40 (and the back portion secondary side member 50) also includes an elongated fastener receiving passage 92 having a slot 94 formed in the bottom surface 82. The fastener receiving passage 92 receives a mechanical fastener, which may be, for example, a Figure 5 and Figure 6 The T-bolts 104 are used to secure the secondary frame 34 to the main frame 12 by securing the secondary side member 40 of the seat portion directly to each ledge 64, utilizing the T-bolts 104 as shown. Figure 5 1 and 1 , and are shown received within the fastener receiving passage 92. Each T-bolt 104 includes a threaded shank 106 and a head 108 that is shaped and sized to fit within the fastener receiving passage 92. The head 108 is shaped and sized to allow the T-bolt 104 to slide linearly within and along the fastener receiving passage 92, but to inhibit axial rotation within the fastener receiving passage 92, and also to restrict movement parallel to the central axis of the threaded shank 106. This allows each T-bolt 104 to be slid along the length of the seat portion secondary side member 40 to a desired position, for example, where the T-bolt 104 is aligned with a corresponding mounting slot 68 in the ledge 64, and then the threaded nut 112 ( Figure 6) is tightened onto the threaded shank 106 of each T-bolt 104, or the threaded nut 112 is removed therefrom without having to hold the head 108 of the T-bolt 104.

[0033] The elongated shape of the mounting slots 68, which are elongated along the longest dimension of the seat portion secondary side member 40, and the fastener receiving passages 92 having slots 94 opening into the bottom surface 82 allow for considerable longitudinal and rotational adjustment of the secondary frame 34 relative to the primary frame 12 during assembly. This adjustment allows assembly of the components to accommodate slight manufacturing errors and other tolerances. The secondary frame 34 is movable relative to the primary frame 12 on the ledge 64 prior to tightening the T-bolts 104 and nuts 112. This arrangement allows for faster and easier assembly because the secondary frame 34 can be positioned on and supported by the ledge 64 with the T-bolts 104 aligned with the mounting slots 68. Conventional sub-frame assemblies are secured to respective conventional frames using bolts disposed parallel (depending on orientation when the conventional recliner is in the use position) directly into threaded inserts of the side members of the frame without the use of supporting ledges. In addition, as the horizontal bolts of the conventional recliner are tightened, the sub-frame assembly may be deformed due to the lateral tension applied by the bolts. In contrast, the ledge 64, as in the illustrated embodiment, provides support for the secondary frame 34, and the threaded shank 106 of each vertically (depending on the orientation when the recliner 10 is in the use position) disposed T-bolt 104 does not laterally strain or otherwise deform the secondary frame 34. Thus, the mechanical fastener, which is a T-bolt 104 in the illustrated embodiment, or another similar bolt, used to secure the secondary frame 34 to the ledge 64 includes a portion, such as the threaded shank 106, extending through the mounting slot 68 in a direction parallel to the weight force exerted on the ledge by the corresponding seat portion secondary side member 40 when the seat portion secondary side member 40 is supported by the ledge 64. In addition, the weight force exerted on the ledge by the seat portion secondary side member 40 causes a normal stress to be generated in the cross-section of the threaded shank 106 extending through the mounting slot 68 perpendicular to the direction of the weight force.

[0034] Reference Figure 7 The cross-sectional profile of each secondary member 40, 50 also includes a hollow space 118, which is used to secure other components to the secondary member 40, 50, such as a hinge 120, as described below. Figure 3 According to the illustrated embodiment, two hinges 120 are used to pivotally connect each hinge end 48 of the corresponding seat portion secondary side member 40 to the corresponding hinge end 58 of the corresponding backrest portion secondary side member 50. Figure 7As shown in FIG. 1 , an example of a hinge 120 is shown, including two nut plates 122, which may be elongated and made of metal, connected to each other along a pivot axis A by a pivot pin 124 (e.g., a rivet). Each nut plate 122 of each hinge 120 may be identical to each other, and each free end 126 opposite the pivot pin 124 is sized and shaped so as to fit snugly within the hollow space 118 of each secondary side member 40, 50 at the respective hinge end 48, 58, as shown in FIG. Figure 8 Each nut plate 122 also includes at least one threaded hole 128 extending through the metal plate parallel to the pivot axis A. Each secondary side member 40, 50 includes at least one hole 130 (in Figure 7 128 (only one of which is visible) extends from the respective inner surface 44, 54 into the hollow space 118 and is aligned with at least one threaded hole 128 when the corresponding nut plate 122 is fully inserted into the hollow space 118 of each secondary side member 40, 50.

[0035] To attach the hinge 120 to the hinge ends 48, 58 of the secondary side members 40, 50, the nut plate 122 of the hinge 120 is inserted into the hollow space 118 of the secondary side members 40, 50. Once inserted, the threaded holes 128 are aligned with the holes 130. To secure the hinge 120, bolts 132 are inserted into the corresponding holes 130 to engage with the threaded holes 128 of the nut plate 122. When the bolts 132 are tightened, the nut plate 122 of the hinge 120 is clamped to the inner wall 134 of each secondary side member 40, 50. This clamping action creates mechanical friction that ensures that the hinge 120 is securely fixed to the secondary side members 40, 50. Over time, if the hinge 120 fails due to fatigue, corrosion, or other reasons and needs to be replaced, a new hinge can be easily installed by simply removing the bolts 132 using an appropriate wrench or other tool. To assemble the seat portion 36 of the secondary frame 34 to the back portion 38 , a hinge 120 is secured to each hinge end 48 , 58 .

[0036] To secure the secondary frame 34 to the primary frame 12, the head 108 of at least one T-bolt 104 is inserted into the fastener receiving passage 92 of the open end 46 of each seat portion secondary side member 40 and the at least one T-bolt 104 is slid along the length of each seat portion secondary side member 40 until the T-bolt 104 is aligned with the at least one mounting slot 68 of each corresponding ledge 64. With the primary frame 12 positioned upright, i.e., in the typical use position of the recliner 10 upon final assembly, the seat portion 36 of the secondary frame 34, with the downwardly directed curved cross members 42, 52, is lowered onto the two ledges 64 and proximate the front end of the primary frame 12. The seat portion 36 can be adjusted longitudinally and transversely until the threaded shank 106 of each T-bolt 104 is aligned with and received by the corresponding mounting slot 68, thereby allowing the secondary frame 34 to rest on and be supported by the ledges 64. A nut 112 is then secured to the threaded shank 106 of each T-bolt 104 and tightened using a suitable tool (eg, a wrench). The seat portion 36 is now secured to the main stage frame 12.

[0037] Although only one T-bolt 104 and nut 112 is required on each seat portion secondary side member 40 to secure the seat portion 36 to the main frame 12, it is preferred that two or more T-bolts and nuts are used along each side flange. Alternatively, although not shown, other types of fasteners may be used to secure the seat portion 36 to the main frame 12, such as strong (N52 strength) neodymium rare earth magnets, locating pins, eccentric latches, or even rubber bands. The use of removable fasteners, such as T-bolts 104 and nuts 112, rather than welding the seat portion 36 to the main frame 12, is to facilitate quick and easy disassembly and repair of the different components of the recliner 10. Therefore, sustainability is achieved because the recliner 10 allows the owner to repair and refurbish their recliner so that the original purchase of the recliner can extend its service life.

[0038] This arrangement allows the backrest portion 38 to be in a completely flat position relative to the main frame 12 during assembly and operation, such as Figure 1 as shown, and the fully raised position, as Figure 2 As shown, the backrest portion 38 pivots between the two parts. This ensures that the backrest portion 38 remains properly and accurately aligned relative to the seat portion 36. Many conventional recliners use two bolts to directly connect the conventional backrest to the frame, which are fixed in two corresponding threaded inserts. This conventional method is prone to misalignment during manufacturing and assembly, and is prone to breakage and wear relatively soon after use. It is known that most components of conventional recliners are typically welded together, and alignment errors are not uncommon. By using the assembly methods and components described herein, the components that make up the recliner 10 are more likely to be aligned when assembled and are more likely to remain aligned during use.

[0039] As described above, when the seat portion 36 is bolted to the main stage frame 12, the back portion 38 will automatically align with the main stage frame 12 and pivot between a fully flat and fully reclined range of motion. The support assembly 150 is used to support the backrest 24 to any of several pre-set recline angles relative to the main stage frame 12 and the seat 26.

[0040] The support member assembly 150 includes a horizontal engagement rod 152 defining opposite engagement ends 154 (at Figure 2 The support struts 156 are connected to the horizontal engagement rod 152 adjacent to each corresponding engagement end 154 and at a predetermined distance therefrom. The distance measured between the support struts 156 is generally close to, but less than, the distance between the backrest portion secondary side members 50 of the backrest portion 38 (see FIG. Figure 3 The support struts 156 are preferably secured to the horizontal engagement rods 152 using a suitable welding process.

[0041] Reference Fig. 9 , the pivot end 158 of each support strut 156 includes a pivot pin 160 that projects outwardly and is parallel to the horizontal engagement rod 152. The support member assembly 150 is pivotally connected to a pivot mount 170 located at a predetermined location along each back portion secondary side member 50. Each pivot mount 170 includes a pivot hole 172 that is sized and oriented to accommodate a corresponding pivot pin 160. Each pivot mount 170 is fixed at a specified location along each back portion secondary side member 50 so that the pivot holes 172 are axially aligned with each other and allow for selective pivotal displacement of the support member assembly 150, wherein the horizontal engagement rod 152 can be manually rotated about the pivot pin 160 to a desired angular position. Each pivot mount 170 is fixed to a pivot mounting plate 174 located within each corresponding fastener receiving channel 92 of each corresponding back portion secondary side member 50. Each pivot mounting plate 174 includes at least one, but preferably two, threaded holes 176 that align with the two holes 178 of each pivot mounting member 170. Fig. 9As shown, each pivot mounting plate 174 is slid into each corresponding fastener receiving channel 92 and positioned in a predetermined position. Each corresponding pivot mounting member 170 is aligned with each corresponding pivot mounting plate 174 so that the corresponding hole 178 is aligned with the corresponding threaded hole 176. Pivot mounting fasteners 180 are used to secure each pivot mounting member 170 to each corresponding pivot mounting plate 174. When the pivot mounting fasteners 180, which can be conventional bolts, are tightened, each pivot mounting member 170 is securely secured to each backrest portion secondary side member 50. The predetermined and correct position of each pivot mounting member 170 can be indicated using indicia 182 located on each backrest portion secondary side member 50, as shown in FIG. Fig. 9 and Fig.10 Each pivot mount 170 can be selectively loosened and repositioned along the length of each corresponding backrest portion secondary side member 50 and removed for cleaning or replacement when necessary. As described above, the support member assembly 150 is mounted on the bottom surface of the backrest portion 38 so that each engagement end 154 extends into and engages with each corresponding ratchet cutout 74 (see Figure 3 ) is engaged with any one of the engagement teeth 76. When the engagement teeth 76 are selected to engage with the horizontal engagement rod 152, the support member assembly 150 will be maintained at a specific angle, which in turn maintains the backrest 24 relative to the seat 26 at a specific angle.

[0042] Open weave textile slings are commonly used in conventional recliners to provide a secure and quick-drying support surface for the occupant of a conventional recliner. Such conventional slings are precisely cut to fit a specific support frame and include an elongated rolled hem pocket formed along two opposing edges. Each rolled hem pocket slides into a slot provided by the side of the conventional recliner frame. A rod is then inserted into each rolled hem pocket. The cross-sectional dimensions of the rod are larger than the dimensions of the slot, so that the rod effectively holds the rolled hem pocket within the frame structure, thereby also securing the opposing edges of the textile sling to the conventional frame. One problem with textile slings used with conventional recliners is that if the sling begins to sag or become damaged over time, the sling cannot be tightened or easily replaced. In this case, the owner's options include attempting to replace the sling, using a relatively complicated process and uncommon tools, and considering replacing the entire recliner.

[0043] Reference Fig.11 , showing a partial perspective view of a recliner 310. The recliner 310 is similar to the recliner 10 described above in that it includes a main frame 12, such as Figure 3 As shown. Fig.11 In the figure, only one corner of the main stage frame 12 is shown, which includes a main stage side member 16, a leg 14 and a main stage cross member 18. The ledge 64 extending vertically from the inner surface 66 of the main stage side member 16 is also shown. Fig.11 middle.

[0044] The recliner 310 also includes a secondary frame (only a portion of which is shown in FIG. Fig.11 ), the frame includes a seat portion and a pivotally connected backrest portion, similar to Figure 3 The secondary frame 34 shown in FIG. The secondary frame of the recliner 310 differs from the recliner 10 described above in the cross-sectional profile of the secondary side members. Fig.11 One seat part secondary side member 340 is shown to have a specific cross-sectional profile, while the other seat part secondary side member 340 (see Fig.12 ) and the backrest portion secondary side member of the secondary frame of the recliner 310 (not shown, but similar to the backrest portion secondary side member 50 described above) have the same cross-sectional profile. Fig.11 and 12 Also shown is a seat section secondary cross member 342 secured to an inner surface 344 of a seat section secondary side member 340. The seat section secondary cross member 342 extends to connect the seat section secondary side members 340 in a manner similar to the seat section secondary cross member 42 described above.

[0045] Special References Fig.11 , the open end 346 of the seat portion secondary side member 340 is shown to show the details of the cross-sectional profile. The seat portion secondary side member 340 includes a top surface 380, a bottom surface 382, ​​an inner surface 344, and an outer surface 384. The cross-sectional profile of the seat portion secondary side member 340 includes a sling anchor receiving channel 386, which is rectangular in cross-section in the illustrated embodiment. The cross-sectional profile of the seat portion secondary side member 340 also includes a sling receiving slot 388 leading to the sling anchor receiving channel 386. Fig.11 In the illustrated embodiment, a sling receiving slot 388 is provided in the top surface 380. Because this is a stretched profile, it is to be understood that these profile features extend the entire length of the seat portion secondary side member 340 (and the back portion secondary side members, which are not shown, but are similar to the back portion secondary side member 50). The sling anchor receiving channel 386 is used to selectively anchor a sling 390 to the seat portion secondary side member 340 by using a sling anchor 392, as will be described in greater detail below, and it is to be understood that a similar sling may be connected in a similar manner to the back portion secondary side member, not shown.

[0046] The cross-sectional profile of the seat portion secondary side member 340 also includes an elongated fastener receiving passage 394 having a slot 396 opening into the bottom surface 382. The fastener receiving passage 394 receives a mechanical fastener, which may be, for example, Figure 5 and Figure 6The T-bolts 104 are used to secure the seat portion secondary side member 340 directly to each ledge 64 in the manner described above with reference to FIG. Figure 4-6 The secondary frame is secured to the primary frame 12 using T-bolts 104. The fastener receiving passage 394 is offset from the sling anchor receiving passage 386 and is offset below the sling anchor receiving passage 386 as shown. The cross-sectional profile of the seat portion secondary side member 340 also includes an elongated hinge receiving passage 398 that can receive the hinge 120 (see FIG. Figure 7 and Figure 8 ) to pivotally connect the seat portion secondary side member 340 to the corresponding back portion secondary side member, in a manner similar to Figure 7 and Figure 8 The method shown.

[0047] The sling anchor 392 is connected to the seat portion secondary side member 340 and is movable relative to the main frame 12 and the seat portion secondary side member 340. Fig.12 and 13 , the threaded fastener 412 is engaged with the sling anchor 392 and the seat portion secondary side member 340. Rotation of the threaded fastener 412 relative to the sling anchor 392 and the seat portion secondary side member 340 causes movement of the sling anchor 392 relative to the seat portion secondary side member 340, which in turn causes movement of the sling 390 relative to the seat portion secondary side member 340. The sling anchor 392 is movable within the sling anchor receiving passage 386 relative to the seat portion secondary side member 340 in a direction perpendicular to the longest dimension of the seat portion secondary side member 340, in response to rotation of the threaded fastener 412. Referring to Fig.13 , a hole 414 located at a designated position along the horizontal inner wall 416 receives a threaded shank 418 of the threaded fastener 412. The horizontal inner wall 416 separates the fastener receiving passage 394 from the sling anchor receiving passage 386. An appropriate cutout 422 may be provided inwardly from the bottom surface 382 so that the head 424 of the threaded fastener 412 may be recessed into the seat portion secondary side member 340, such as Fig.13 shown.

[0048] Reference Fig.12 The sling 390 is located between the seat portion secondary side members 340 and fixed thereto, as described below. Similar slings 390 are also located between the backrest portion secondary side members and fixed in a similar manner. The slings 390 are typically made of a strong, inelastic woven fabric.

[0049] The size and shape of the sling anchor 392 are defined to fit within the sling anchor receiving channel 386. The width of the sling anchor 392 is slightly smaller than the width of the sling anchor receiving channel 386 so that the sling anchor 392 can slide freely up and down therein (according to the Fig.12 ). The height of the sling anchor 392 is preferably about half the height of the sling anchor receiving channel 386 so that the sling anchor 392 can slide a considerable distance within the sling anchor receiving channel 386. The greater the vertical displacement distance of the sling anchor 392 within the sling anchor receiving channel 386, the greater the tension of the sling 390 between the seat portion secondary side member 340 (and the back portion secondary side member) can be. The sling anchor 392 can be in an elevated position within the sling anchor receiving channel 386, such as Fig.11 as shown, and the lowered position, as Fig.13 The sling anchor 392 is preferably made of extruded aluminum and defines a sling receiving channel 432, an upper surface 434, and a sling receiving slot 436 to provide access to the sling receiving channel 432. When the sling anchor 392 is properly positioned within the sling anchor receiving channel 386, the sling receiving slot 436 of the sling anchor 392 is aligned with the sling receiving slot 388 of the seat portion secondary side member 340 so that a portion of the sling 390 can pass through the sling receiving slot 436 and the sling receiving slot 388, and the edge 440 of the sling 390, which can be a hemming pocket, is received within the sling receiving channel 432 together with the anchor rod 442. The diameter (or cross-sectional dimension) of the anchor rod 442 is greater than the width of the sling receiving slot 436 so that when the anchor rod 442 is received into the hemming pocket at the edge 440, the edge 440 is retained in the sling receiving channel 432. The diameter (or cross-sectional dimension) of the anchor rod 442 may also be greater than the width of the sling receiving slot 388 .

[0050] Reference Fig.13, a threaded hole 452 is provided through a side portion of the sling anchor 392 and is aligned with the hole 414 in the horizontal interior wall 416 so that the threaded shank 418 of the threaded fastener 412 can reside in the hole 414 and the threads of the threaded shank 418 can engage the threaded hole 452. This arrangement allows the threaded fastener 412 to be selectively rotated to mechanically raise or lower the sling anchor 392 between its raised and lowered positions. Because the edge 440 of the sling 390 is fixed in the respective sling receiving channel 432, the controlled vertical displacement of the sling anchor 392 of the threaded fastener 412 is utilized to tighten and loosen the sling 390. In use, a maintenance personnel can use a tool, such as an Allen wrench (not shown) to rotate the threaded fastener 412 counterclockwise to loosen the sling 390 so that the tension is reduced sufficiently to longitudinally remove the anchor rod 442, thereby allowing the edge 440 to be removed from the sling receiving slot 436 and the sling receiving groove 388. Similarly, maintenance personnel may pull the sling anchor 392 downward within the sling anchor receiving channel 386 by rotating the threaded fastener 412 clockwise, thereby effectively tightening the sling 390, which may, for example, sag.

[0051] Due to the amount of tension when tightening the sling 390, the threaded fastener 412 may be made of steel. The threaded hole 452 located in the sling anchor 392 may be made of aluminum, which may not be strong enough to withstand the tension caused by the tightened sling and may strip during the tightening process. In order to strengthen the threaded engagement between the threaded fastener 412 and the sling anchor 392, a steel insert 460 having a threaded hole 462 may be provided. The size, shape and positioning of the threaded hole 462 are defined to engage with the threaded shank 418 of the threaded fastener 412. Using the threaded fastener 412 and the steel insert 460, which may be made of steel, sufficient engagement strength can be provided to generate the tension required by the sling 390 to provide support to the occupant during normal use of the recliner 310. In order to accommodate the steel insert 460, the sling anchor 392 may include a rectangular lower channel 464 in which the steel insert 460 can be positioned. The steel insert 460 may be provided in the form of an elongated steel strip shaped to fit within the rectangular lower channel 464, the length of which is generally equal to the length of the seat portion secondary side member 340. Threaded holes 462 will be formed at specified points along the length of the steel insert 460 so that each threaded hole 462 is aligned with each threaded fastener 412 located on the seat portion secondary side member 340. If a steel insert 460 is used, the threaded hole 452 described above will have a diameter slightly larger than the diameter of the threaded shank 418 and may no longer be threaded so that the threaded shank 418 does not engage the sling anchor 392 directly, but rather indirectly through engagement with the steel insert 460, which in turn will pull or push the sling anchor 392 during rotation of the threaded fastener 412.

[0052] In use, such as Fig.13As shown, when the threaded fastener 412 is rotated clockwise, the threads of the threaded shank 418 will engage the threads of the threaded hole 462 in the steel insert 460 and will force the steel insert 460 to move downward within the sling anchor receiving channel 386. This action will also pull down the sling anchor 392, which in turn will also pull down the attached sling 390. As the sling 390 is pulled vertically down within the sling anchor receiving channel 386, the tension of the sling 390 on the parallel and spaced seat portion secondary side members 340 will increase, as shown in FIG. Fig.13 460. Alternatively, a barrel nut (not shown) may be used at each bolt location in place of the steel insert 460. This would allow each threaded fastener 412 to rotate slightly during tightening of the sling anchor 392. In another alternative arrangement, the sling anchor 392 may include aluminum filling the void provided by the rectangular lower channel 464, and this relatively thick section of material may include the threaded hole 452, which is likely sufficient to maintain the force applied when tensioning the sling 390. Thus, the sling anchor 392 may include a thickened section of material, which may be aluminum or steel, disposed below the sling receiving channel 432 (depending on the orientation when the recliner is in use) that is at least half the height of the sling receiving channel 432. The threaded fastener 412 engages with this thickened section of material, which may include the steel insert 460, the barrel nut described above, and the aluminum filling the void provided by the rectangular lower channel 464 to provide a sufficient section of material to maintain the force applied when tensioning the sling 390.

[0053] If desired, the sling anchor 392 and the steel insert 460 (if provided) can be segmented within the interior of the corresponding seat portion secondary side member 340. By providing separate segments of the sling anchor 392 and the steel insert 460 (if provided), this arrangement will allow different areas of the sling 390 to be tightened independently of other areas. This arrangement may be particularly beneficial for outdoor recliners because certain areas of the sling 390 tend to sag before other areas during extended use, such as the area under the abdomen of the occupant. Similarly, both the sling anchor 392 and the sling 390 can be equally segmented, with each different segment of the sling anchor 392 connected to a different segment of the sling 390. This arrangement will allow tightening, re-tightening, and even replacement of a specific single sling segment, independent of other sling segments of the recliner. In addition, the type of material, amount of fill, amount of rebound, and other characteristics can be selected for each specific segment. For example, a sling segment located on the seat portion adjacent to the backrest portion (the portion where the occupant sits) can provide thicker padding to provide comfort to the occupant during use.

[0054] Reference Fig.14, an alternative (or second) sling anchor 502 is shown connected to a seat portion secondary side member 340, for example, on the left side of the recliner 310. The alternative sling anchor 502 can be an elongated extrusion made of plastic or aluminum and is sized and shaped so as to fit snugly into the sling anchor receiving channel 386. The alternative sling anchor 502 is generally equal to the length of the sling 390 and includes an upper sling edge receiving channel 504, a middle sling edge receiving channel 506, and a lower sling edge receiving channel 508. In the illustrated embodiment, multiple sling edge receiving channels are provided, but a single sling edge receiving channel can still work properly. Each of the upper sling edge receiving channel 504, the middle sling edge receiving channel 506, and the lower sling edge receiving channel 508 is connected to a channel 510, which extends to and opens at an upper surface 512 of the alternative sling anchor 502 and is aligned with the sling receiving slot 388 of the seat portion secondary side member 340. Each of the upper sling edge receiving channel 504, the middle sling edge receiving channel 506, and the lower sling edge receiving channel 508 is configured to receive an edge 440 of the sling 390, which may be a hemming pocket. The edge 440 may be inserted into any of the upper sling edge receiving channel 504, the middle sling edge receiving channel 506, and the lower sling edge receiving channel 508, and then the edge 440 may be locked in place by inserting the anchor rod 442 into the hemming pocket.

[0055] In use, when the sling 390 is first installed, the sling 390 will be tightened and cut to a width that matches the distance between the upper sling edge receiving channel 504, such as on the left side of the recliner 310, and the sling receiving channel 432, such as on the right side of the recliner 310, when the sling anchor 392 is in the raised position, such as Fig.11 As shown. During use of the recliner 310, the sling 390 will begin to sag and stretch, causing the effective sling width to increase. Then, as described above, the individual can tighten the slack in the sling 390 by tightening each threaded fastener 412 so that the sling anchor 392 moves from the raised position to the lowered position and tightens again.

[0056] During continued use, the sling 390 may loosen again, but the sling anchor 392 may not move further downward because it may be in a lowered position, such as Fig.13As shown. The operator can rotate each threaded fastener 412 to raise the sling anchor 392 back to its raised position and then reposition the opposite edge 440 of the sling 390 from the upper sling edge receiving channel 504 to the middle sling edge receiving channel 506. Since the middle sling edge receiving channel 506 is located below the upper sling edge receiving channel 504, moving the edge 440 to this new position will effectively tighten the sling 390. When the edge 440 is anchored in the middle sling edge receiving channel 506, the sling anchor 392 can be tightened slightly to restore the sling 390 to the desired tension. Additional use may cause additional sagging and the lower sling edge receiving channel 508 may have to be used.

[0057] An elongated ridge 520 may be disposed within the seat portion secondary side member 340 and extend downwardly into the sling anchor receiving passage 386. The elongated ridge 520 is aligned with an elongated slot 522 formed in the upper surface 512 of the sling anchor receiving passage 386. When the alternative sling anchor 502 is positioned within the sling anchor receiving passage 386, the elongated ridge 520 engages within the elongated slot 522. This engagement inhibits lateral movement of the alternative sling anchor 502 within the sling anchor receiving passage 386 caused by lateral stretching of the sling 390. The alternative sling anchor 502 is shown as a separate component that is sized and shaped to fit snugly within the sling anchor receiving passage 386; however, the alternative sling anchor 502 may be integrally formed with the seat portion secondary side member 340 if desired.

[0058] Fig.15 The sling 90 (see Figure 1 and Fig.16 ) Installation and removal to Figure 3 The system and method are shown on the seat portion secondary side member 40 or the back portion secondary side member 50. The system and method of installing and removing the sling 90 will be specifically described with reference to the seat portion secondary side member 40, but because the back portion secondary side member 50 can have the same cross-section and can be formed by the same extrusion process, the installation and removal on the back portion secondary side member 50 will be the same.

[0059] Reference Fig.15 , a bracket 540 is provided for temporary attachment to each seat portion secondary side member 40. Each bracket 540 includes an eyelet 542 and a mounting section 544. In the illustrated embodiment, each mounting section 544 has a T-shaped cross-section, which is sized and shaped to be received in an elongated fastener receiving passage 92 having a slot 94 opening at the bottom surface 82 (see FIG. Figure 4) along the seat portion secondary side member 40. This allows each mounting segment 544 of each bracket 540 to be easily engaged within the elongated fastener receiving channel 92. In the illustrated embodiment, multiple pairs of brackets 540 are fixed to the opposing seat portion secondary side members 40 so that the brackets 540 of each pair are laterally aligned with each other and so that each pair of brackets is along the secondary frame 34 ( Figure 3 The lengths of the cross members 42, 52 are evenly distributed, preferably located near each corresponding curved cross member 42, 52.

[0060] Rope 546 may be connected and configured to span between each bracket. Fig.15 As shown, a rope 546 is connected to each eyelet 542 of each bracket 540 in each pair of brackets. When connected to the brackets 540, the rope 546 can be arranged or twisted to form loops 548 in a braided pattern, and preferably to form a plurality of loops, which are arranged in a plurality of pairs of brackets. Fig.15 and 16 546 is shown as a two-strand pattern, but can be a multi-strand pattern, depending on the composition of the rope 546. The rope 546 can be made of a very strong material with high tensile strength, such as a polyester braided rope.

[0061] Torsion member 550, which may be an elongated rigid rod, such as Fig.15 The twisting member 550 is shown positioned within the corresponding loop 548 and rotated as shown by arrow 552 to cause the rope 546 to begin twisting. The twisting member 550 is configured to engage with the rope 546 and be manipulated by the operator to twist the rope 546 when the rope 546 engages with the bracket 540 and spans therebetween. As the rope 546 is twisted, the twisted rope 546 tightens itself, causing its effective length to shorten. As the length of the twisted rope 546 decreases, the twisted rope 546 pulls the seat portion secondary side members 40 toward each other. The amount of lateral displacement can be controlled by counting the number of rotations during twisting. The twisting member 550 can be made of wood, plastic, or metal and is strong and long enough to provide sufficient leverage to allow the person installing or removing the sling to twist the rope 546 and pull the seat portion secondary side members 40 together to counter the bias of the welded curved cross member 42. Once the desired amount of lateral displacement is achieved, the twisting member 550 can be placed on a nearby curved cross member 52, such as Fig.15 As shown, the rope 546 is unfolded to secure and prevent it from being twisted.

[0062] When each twisted rope 546 is properly tightened, the seat portion secondary side members 40 will move slightly closer to each other, which will effectively cause the sling 90 to loosen. Because the tension of each twisted rope 546 passes through each corresponding bracket 540 and through each elongated fastener receiving channel 92 (see Figure 4) is applied to each corresponding seat portion secondary side member 40 so that the sling 90 and the C-shaped channel 86 remain fully accessible so that the hemming pockets 556 at each edge of the sling 90 can be easily slid into the C-shaped channel 86 of each seat portion secondary side member 40. After the hemming pockets 556 are fully installed in the circular C-shaped channel 86, the anchor rods 558 can be inserted into the hemming pockets 556 to lock the sling 90 to the seat portion secondary side member 40, as shown in FIG. Fig.16 shown.

[0063] Special reference Fig.15 and Fig.16 , the ropes 546 are fixed to each seat portion secondary side member 40, which are parallel and spaced a first distance from each other before the ropes 546 are twisted by the operator. Fig.15 and 16 In the embodiment of the present invention, the rope 546 is fixed to each seat portion secondary side member 40 by the bracket 540. Then, the rope 546 is twisted to bring the seat portion secondary side members 40 closer to each other, so that the seat portion secondary side members 40 are spaced apart from each other by a second distance, which is less than the first distance. Then, the sling 90 is removed from each seat portion secondary side member 40 or connected thereto in the above-mentioned manner. The rope 546 can then be untied to return the seat portion secondary side members 40 to the first distance between each other.

[0064] To facilitate attachment of the cord 546 to the bracket 540, a clip 560 may be provided at each end of the cord 546 that operates similarly to a carabiner, although in Fig.15 Only one is specifically shown in the drawings. The clip 540 includes a door 562, which may be spring loaded, connected to a door mount 564 via a rivet pin 566. The door mount 564 is connected to one end of the rope member 546. A clip frame 568 is connected to the other end of the rope member 546 and cooperates with the door 562, similar to how the door and frame in a conventional carabiner cooperate with each other. The door 562 can be rotated relative to the door mount 564 to allow the clip frame 568 to hook the bracket 540 within the eyelet 542 before the door 562 is rotated back to engage the clip frame 568. The clip 540 provides a simple connection of the rope member 546 to the bracket 540, although other types of connections may be provided. Therefore, at least one clip 540 can be provided at one end of the rope member 546, wherein the clip 560 is configured to selectively connect to at least one of the brackets 540.

[0065] The sling 90 can be removed from the seat portion secondary side member 40 by squeezing the seat portion secondary side member 40 together as described above using the rope 546, bracket 540 and torsion member 550. The anchor rod 558 can then be pulled out of each hemming pocket 556, allowing the sling 90 to be removed from the seat portion secondary side member 40.

[0066] Fig.17 A primary sling 576 and a secondary sling 580 are shown secured to and spanning each side member 582, which may function similarly to Figure 3 The seat part secondary side member 40 and the backrest part secondary side member 50 are shown. However, Fig.17 The side member 582 shown in FIG. Figure 3 The seat portion secondary side member 40 and the back portion secondary side member 50 shown in FIG. 5 have slightly different cross-sectional profiles to allow for the connection of the primary sling 576 and the secondary sling 580 .

[0067] Each side member 582 includes an extruded profile 584 defining a primary sling anchor channel 584, which is sized and shaped to receive and retain the opposite edge of the primary sling 576, and a secondary sling anchor channel 586, which is sized and shaped to receive and retain the opposite edge of the secondary sling 580. The secondary sling 580 is generally parallel to the primary sling 576 and a predetermined distance below it. The secondary sling 580 can be located below the entire primary sling 576, or only below a selected area thereof. The purpose of the secondary sling 580 is to provide auxiliary support for the primary sling 576, such as when the primary sling 576 sags due to aging and / or due to excessive load, such as when supporting heavy objects, or areas on the recliner that are subject to concentrated loads, such as below the abdomen or hips of the occupant during use. The secondary sling 580 can be made of the same material as the primary sling 576, or it can be made of a different material, such as a material with higher strength and less elasticity.

[0068] In addition to the primary and secondary sling anchor passages 584, 586, the extruded profile of each side member 582 may also include an elongated fastener receiving passage 592 having a slot 594 opening at a bottom surface 596 of the side member 582, which may be similar in shape and function to that of the elongated fastener receiving passage 592. Figure 4 The slot 94 is shown opening at the bottom surface 82. In addition, the cross-sectional profile of each side member 582 also includes a hollow space 598, which can be used to secure a hinge, such as Figure 7 and Figure 8 Thus, a hinge 120 with a cross member (not shown, but similar to Figure 3 The side members 582 of the curved cross members 42, 52 shown in FIG. 5 can be assembled similar to Figure 3The secondary frame of the secondary frame 34 shown in FIG.

[0069] Reference now Fig.18 , showing the right side member 610, which may function similarly to Figure 3 The seat portion secondary side member 40 and the back portion secondary side member 50 are shown. For clarity, only the right side member 610 is described. The left side member will contain the same structure and features. The right side member 610 can be made of aluminum or plastic extrusions with a specific extrusion profile. The right side member 610 includes a hinge channel 602, which is sized, shaped and positioned to tightly accommodate a hinge plate 606 of a hinge 608, which can be used to connect the right side member 610, which can be similar to Figure 3 The seat portion of the seat portion 36 of the secondary frame 34 shown may be another similar side member, which may be similar to Figure 3 The back portion 38 of the secondary frame 34 is shown. Hinge 608 is one of two hinges that can pivotally connect the back portion to the seat portion.

[0070] The right side member 610 also includes an upper slat receiving channel 612, which includes a side opening 614 ( Fig.18 618). The slat receiving channels 612 are sized and shaped to receive the ends 616 of corresponding slats 618. The slats 618 can be made of a variety of materials, such as wood, plastic, metal, or a laminate made of two or more different materials, such as metal coated with vinyl plastic. The ends 616 of the slats 618 are sized and shaped so as to fit snugly in the slat receiving channels 612 of the right side member 610, and in the opposing left side member (not shown), through similar channel openings. The end result is that the right side member 610 and the left side member (not shown) work together to secure a plurality of laterally positioned slats 618, which together form an occupant support member that defines a support surface, either directly for the occupant, or indirectly through a support cushion, not shown.

[0071] The right side member 610 also includes a longitudinal screw access channel 620. A threadable screw hole 622 is provided between the screw access channel 620 and the slat receiving channel 612 and is aligned with a corresponding end 616 of each slat 618 located within the slat receiving channel 612. A screw 624 is threaded into the screw hole 622 and engages with the end 616 of the slat 618 to secure the slat 618 to the right side member 610. Each slat 618 can be provided with a lower notch 626 that can receive the screw 624 when it passes through the screw hole 622 and the end 616 of the slat 618 is received in the slat receiving channel 612. At least one screw 224 can be used to insert each slat 618 in the right side member 610 (and the left side member, not shown). The use of the screw 624 allows the slats 618 to be spaced apart from each other, preventing the slats 618 from sliding longitudinally within the slat receiving channel 612. However, screws 224 are not required, as the slats 618 may include spacers (not shown) that reside only within the slat receiving channels 612, which function to effectively space each slat 618 a predetermined distance from one another. In addition, the slats 618 may be arranged so that each slat abuts against an adjacent slat, thereby maintaining the correct position of each slat within the side member. The screws 624 may be selected based on the type of material used to manufacture the slats 618, and a common type of No. 8 size pan head cross drive sheet metal screw may be suitable for wood, plastic, and metal types of slats, as long as the metal slats are made of hollow sheet metal box structure.

[0072] like Fig.18 As shown, the screw access channel 620 includes an opening 628 at the lower end through which the screws 624 can be inserted to reach their respective screw holes 622, and a corresponding screw rotation tool. The opening 628 at the lower end of the screw access channel 620 may include two flanges 630 for connecting with the T-bolt 104 (see Figure 3 ) with, for example, similar to the above reference Figures 3 to 6 The side members are fixed to the main frame 12 in a manner similar to Figure 3 The main frame shown and similar Figure 3 The secondary frame 34 shown differs in that the side members and the extruded profile of the slats 618 are replaced by Figure 1 The sling 90 is shown.

[0073] Reference Fig.19 , an end cap 660 is provided to cover the open end 46 of each seat portion secondary side member 40 (see Figure 1 ), and the open end 56 of each backrest portion secondary side member 50. Figure 1As shown, the end cap 60 for each back portion secondary side member 50 may include an integrally formed base pad 662 to protect each back portion secondary side member 50 when the back portion 38 is lowered relative to the main stage frame 12 .

[0074] The above has been described in detail with respect to an example of a reclining chair. After reading the above detailed description, modifications and alterations will occur to those. However, the present invention is not limited to the above-described embodiments. It will be appreciated that the various embodiments and other features and functions disclosed above, or alternatives or variations thereof, may be ideally combined into many other different systems or applications. Moreover, various currently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may subsequently be made by those skilled in the art, which modifications, alterations or improvements are also intended to be included in the following claims.

Claims

1. A reclining chair, characterized in that: The reclining chair comprises: a frame comprising at least two side members, at least one cross member connecting the at least two side members, and a plurality of legs; a first sling anchor connected to a first side member of the at least two side members and movable relative to the frame; a second sling anchor connected to a second side member of the at least two side members, the second side member being disposed on an opposite side of the frame from the first side member; a sling secured to the first sling anchor and the second sling anchor and spanning between the first side member and the second side member, the sling defining a support surface upon which an associated occupant may selectively reside; and A threaded fastener is engaged with the first sling anchor and the first side member, wherein rotation of the threaded fastener relative to at least one of the first sling anchor and the first side member causes the first sling anchor to move relative to the first side member, thereby causing the sling to move relative to the first side member.

2. The reclining chair according to claim 1, characterized in that: The second sling anchor is movable relative to the frame, and the threaded fastener is a first threaded fastener, the recliner further comprising a second threaded fastener engaged with the second sling anchor and the second side member, wherein rotation of the second threaded fastener relative to at least one of the second sling anchor and the second side member causes the second sling anchor to move relative to the second side member, thereby causing the sling to move relative to the second side member.

3. The reclining chair according to claim 1, characterized in that: The first side member includes a sling anchor receiving channel in which the first sling anchor is received.

4. The reclining chair according to claim 3, characterized in that: The first sling anchor is movable within the sling anchor receiving channel relative to the first side member in a direction perpendicular to the longest dimension of the first side member in response to rotation of the threaded fastener.

5. The reclining chair according to claim 3, characterized in that: The framework includes: a main stage frame comprising at least two main stage side members connected by at least one main stage cross member, and said plurality of legs, a secondary frame comprising at least two secondary side members connected by at least one secondary cross member, the secondary frame being sized and shaped to be supported by the primary frame, wherein the first side member is one of the at least two secondary side members and includes a fastener receiving channel offset from the sling anchor receiving channel, and The recliner also includes a mechanical fastener at least partially received in the fastener receiving channel for securing the first side member to one of the at least two primary side members.

6. The reclining chair according to claim 5, characterized in that: The primary stage frame includes a ledge protruding inwardly from at least one of the at least two primary stage side members toward another of the at least two primary stage side members, the ledge including at least one mounting slot extending therein.

7. The reclining chair according to claim 6, characterized in that: The recliner also includes at least one mechanical fastener for securing the secondary frame to the wall bracket, the at least one mechanical fastener including a portion extending through the at least one mounting slot in a direction parallel to a gravity force exerted on the wall bracket by at least one secondary side member when the at least one secondary side member is supported by the wall bracket.

8. The reclining chair according to claim 7, characterized in that: The at least one mechanical fastener includes a shank and a head, wherein the shank includes a portion of the at least one mechanical fastener extending through the at least one mounting slot to secure the first side member to one of the at least two primary side members.

9. The reclining chair according to claim 8, characterized in that: The fastener receiving channel is sized and shaped to slidingly receive the head of the at least one mechanical fastener, and the fastener receiving channel is shaped to allow longitudinal displacement of the at least one mechanical fastener along the longest dimension of the first side member and to inhibit rotation of the handle relative to the first side member.

10. The reclining chair according to claim 3, characterized in that: The first side member includes a sling receiving slot leading to the sling anchor receiving channel, wherein the sling extends through the sling receiving slot when received in the sling anchor receiving channel.

11. The reclining chair according to claim 10, characterized in that: The first sling anchor includes a sling receiving slot leading to a sling receiving passage, wherein the sling extends through the sling receiving slot when received in the sling receiving passage.

12. The reclining chair according to claim 11, characterized in that: The sling includes a hemming pocket along a first edge, and an anchor rod is received in the hemming pocket to retain the first edge in the sling receiving channel, wherein a diameter of the anchor rod is greater than a width of the sling receiving slot.

13. The reclining chair according to claim 3, characterized in that: The first side member includes a material thickening section, which may be aluminum or steel and is disposed below the sling receiving channel, the material thickening section being at least one-half the height of the sling receiving channel.

14. The reclining chair according to claim 1, characterized in that: The second sling anchor includes a plurality of sling edge receiving channels, wherein a first edge of the sling is secured to the first sling anchor and each of the plurality of sling edge receiving channels is configured to receive a second edge of the sling, the second edge being opposite the first edge.

15. The reclining chair according to claim 14, characterized in that The plurality of sling edge receiving channels include an upper sling edge receiving channel, a middle sling edge receiving channel, and a lower sling edge receiving channel.

16. A system for installing a sling on a reclining chair, characterized in that The system comprises a frame comprising two parallel and spaced-apart side members connected by at least one cross member, the system comprising: a first bracket configured to be connected to a first side member of the two parallel and spaced-apart side members; a second bracket configured to connect to a second side member of the two parallel and spaced-apart side members; a rope member connectable to and configured to span between the first bracket and the second bracket; and A twisting member is configured to engage the rope and is operable by an operator to twist the rope when the rope is engaged with and spans between the first bracket and the second bracket.

17. The system according to claim 16, characterized in that Each of the first bracket and the second bracket includes an eyelet and a mounting segment configured to engage a channel provided in each of the first side member and the second side member.

18. The system according to claim 16, characterized in that The torsion member is an elongated rod.

19. The system according to claim 16, characterized in that The rope is provided with or twisted to form at least one loop, wherein the twisting member is located within the corresponding loop when engaged with the rope.

20. The system according to claim 16, characterized in that The system further includes at least one clip disposed at one end of the cord, the at least one clip being configured to selectively couple with at least one of the first bracket and the second bracket.

21. A method for installing a sling on a reclining chair, characterized in that: The system includes a frame including two parallel and spaced-apart side members connected by at least one cross member, the method comprising: securing a rope to each of the two parallel and spaced-apart side members when the two parallel and spaced-apart side members are spaced a first distance from each other; twisting the rope to bring the two parallel and spaced-apart side members closer to each other so that the two parallel and spaced-apart side members are spaced a second distance from each other, the second distance being less than the first distance; connecting the sling to each of the two parallel and spaced-apart side members when the two parallel and spaced-apart side members are spaced the second distance from each other; and The rope is untied to return the two parallel and spaced-apart side members to the first distance from each other with the sling connected to each side member.

22. A reclining chair, characterized in that: The reclining chair comprises: a main stage frame comprising at least two main stage side members connected by at least one main stage cross member, and a ledge projecting inwardly from at least one of the at least two main stage side members toward another of the at least two main stage side members, wherein the ledge includes at least one mounting slot extending therein; a secondary frame comprising at least two secondary side members connected by at least one secondary cross member, the secondary frame being sized and shaped so that at least one of the at least two secondary side members is aligned with and supported by the ledge; an occupant support secured to each of the at least two secondary side members and spanning between the at least two secondary side members, the occupant support defining a support surface upon which an associated occupant may selectively reside; and At least one mechanical fastener for securing the secondary frame to the ledge, the at least one mechanical fastener comprising a portion extending through the at least one mounting slot in a direction parallel to a gravity force exerted on the ledge by the at least one secondary side member when the at least one secondary side member is supported by the ledge.

23. The reclining chair according to claim 22, characterized in that The gravity force exerted on the ledge by the at least one secondary side member causes a normal stress to be generated in a cross-section of the portion of the at least one mechanical fastener extending through the at least one mounting slot perpendicular to the direction of the gravity force.

24. The reclining chair according to claim 22, characterized in that The at least one mechanical fastener includes a shank and a head, wherein the shank includes a portion of the at least one mechanical fastener that extends through the at least one mounting slot.

25. The reclining chair according to claim 24, characterized in that The at least one secondary side member includes an elongated channel, the elongated channel including a fastener receiving section, the size and shape of which are defined so as to slidingly receive the head of the at least one mechanical fastener, and the shape of which is defined so as to allow longitudinal displacement of the at least one mechanical fastener along the longest dimension of the at least one secondary side member and to prohibit displacement of the at least one mechanical fastener in a direction perpendicular to the axial direction of the handle.

26. The reclining chair according to claim 25, characterized in that The fastener receiving section of the elongated channel is sized and shaped to inhibit rotational movement of the at least one mechanical fastener about an axial direction of the shank.

27. The reclining chair according to claim 26, characterized in that The shank is threaded.

28. The reclining chair according to claim 25, characterized in that The at least one secondary side member includes another elongated channel including an occupant support receiving section sized and shaped to be shaped in accordance with at least a portion of the occupant support.

29. The reclining chair according to claim 22, characterized in that The at least one mounting slot extending through the ledge is elongated along the longest dimension of the at least one secondary side member.

30. The reclining chair according to claim 22, characterized in that The secondary frame includes a seat portion and a back portion pivotally connected to the seat portion, and the at least one secondary side member aligned with and supported by the ledge is a seat portion secondary side member associated with the seat portion.

31. The reclining chair according to claim 30, characterized in that The secondary frame includes a support member pivotally connected to the backrest portion, the support member selectively engaging with the main frame to support the backrest portion at a specified angle relative to the main frame, wherein at least two secondary side members include a backrest portion secondary side member associated with the backrest portion, the backrest portion secondary side member being identical in cross-section to the seat portion secondary side member, the cross-section being perpendicular to the longest dimension of each of the backrest portion secondary side member and the seat portion secondary side member.

32. The reclining chair according to claim 31, characterized in that The secondary frame includes a hinge connecting the back portion secondary side member and the seat portion secondary side member, and each of the back portion secondary side member and the seat portion secondary side member includes a hinge channel sized and shaped to receive a corresponding portion of the hinge.

33. The reclining chair according to claim 31, characterized in that The secondary frame includes a pivot mounting plate, a pivot mounting member and a pivot mounting fastener, wherein the backrest portion secondary side member includes an elongated channel, the elongated channel includes a fastener receiving section, the size and shape of the fastener receiving section are defined so as to slidingly receive the pivot mounting plate, the pivot mounting member is connected to the pivot mounting plate via the pivot mounting fastener, and the backrest portion includes at least one support post having a pivot pin connected thereto, the pivot pin being pivotally connected to the pivot mounting member.

34. The reclining chair according to claim 22, characterized in that The occupant support is a primary sling, and the recliner further includes a secondary sling disposed below the primary sling and secured to each of and spanning between the at least two secondary side members.

35. The reclining chair according to claim 34, characterized in that The at least two secondary side members each include a primary sling anchor channel sized and shaped to receive and retain an edge of the primary sling and a secondary sling anchor channel sized and shaped to receive and retain an edge of the secondary sling.

36. The reclining chair according to claim 22, characterized in that The occupant support includes at least one slat having ends sized and shaped to be received in a corresponding slat receiving channel provided in each of the at least two secondary side members.

37. The reclining chair according to claim 36, characterized in that Each of the at least two secondary side members includes a screw hole leading to the slat receiving channel, and the recliner further includes a screw threaded within the screw hole and engaged with the slat.

38. The reclining chair according to claim 36, characterized in that The at least one slat is provided with a lower notch for receiving the screw when the screw passes through the screw hole.

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