Wood-to-floor recliner mechanism with projected back pivot point
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-05-06
- Publication Date
- 2026-03-18
Smart Images
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Figure 000026 
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Abstract
Description
WOOD-TO-FLOOR RECLINER MECHANISM WITH PROJECTED BACK PIVOT POINTBACKGROUND
[0001] Recliners are generally well known in the furniture industry. The term recliner is used throughout this description to describe articles of furniture that include a reclining mechanism. Generally recliners having reclining mechanisms are chairs that allow the user to recline and are equipped with one or more extendable ottomans. Recliners are often in the form of a plush chair, however, they might also take the form of an oversized seat, a seat-and-a-half, a love seat, a sofa, a sectional, and the like. Recliners are known in both a manual configuration (where the user releases the reclining mechanism from a closed position to a TV position, and moves the reclining mechanism from the TV position to a full recline position) and a motorized version (where a motor is used to move the mechanism between the various positions) .
[0002] The reclining motion is achieved in recliners with a linkage mechanism that is coupled to a base. The linkage mechanisms found in recliners in the art include a plurality of interconnected links that provide one or more mechanisms for extending and retracting a footrest, and reclining and returning to upright a back of the recliner. Typically, recliners known in the art provide three positions: an upright seated position with the footrest retracted beneath the chair (the “closed position” ) ; a television viewing position in which the chair back is slightly reclined but still provides a generally upright position with the footrest extended (the “TV position” ) , and a fully reclined position in which the chair back is reclined an additional amount farther than in the TV position but still generally inclined with respect to the seat of the chair and with the footrest extended (the “fully reclined position” ) . In some recliners, the mechanism includes a metal base that rests on the floor. These mechanisms are generally known as “metal-to-the-floor” mechanisms. The styling of these chairs is limited in that the sides of the chair must extend to the floor, or close to the floor, to obscure the metal of the linkage mechanism. In other recliners, the mechanism may be designed to be coupled to the side (or arm) of the chair, such that the metal does not extend all the way to the floor. These mechanisms are generally known as “wood-to-the-floor” mechanisms.
[0003] These types of prior art recliner mechanisms, while functional, suffer from a number of drawbacks. One of which includes a problem known as shirt pull. Shirt pull occurs as the user reclines the back of the chair, and the chair back rotates back, but also away from the seat, increasing the distance between the bottom of the back cushion and the back of the seat cushion. This movement not only results in shirt pull, but also removes support from the lower lumbar area of the user seated in the chair. In some cases, a gap may form between the seat cushion and the back cushion resulting in discomfort to the user seated in the chair. This motion is caused by a back bracket pivot point that is typically below and behind the point where the chair back cushion and the seat cushion meet. It would be desirable to provide a recliner, whether manual or motorized, having a back pivot point projected to as close as possible to the point at which the bottom of the back cushion and the back of the seat cushion meet.
[0004] Further, as a chair reclines, the back rotates rearwardly, requiring the chair to be placed a distance away from a wall to allow the movement of the back. It would be desirable to provide a recliner having a required wall clearance as small as possible, to allow the user as much freedom as possible when positioning the recliner in a room.
[0005] BRIEF SUMMARY
[0006] Embodiments of the invention are defined by the claims below, not this summary. A high-level overview of various aspects of the invention are provided here for that reason, to provide an overview of the disclosure, and to introduce a selection of concepts that are further described below in the detailed-description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in isolation to determine the scope of the claimed subject matter.
[0007] In aspects of the invention a compact linkage for use in wood-to-the-floor reclining furniture is described. The linkage includes a back bracket indirectly supported above a seat rail, or seat rail extension. The resulting pivot point for the back of the recliner is projected upwardly and forwardly, to a point where an upholstered back and seat meet on a finished chair, resulting in far less shirt pull than in previously known mechanisms and chairs. During recline, the bottom of the back of the chair will follow the user, offering full support of the user’s back and avoid the undesirable gap between cushions, even in the full-recline position. The back bracket rotating about the projected pivot point in the linkage described above allows for a decreased minimum wall clearance than in previously known mechanisms and chairs. When the recliner moves from the closed position to the fully reclined position, the back bracket moves forward allowing the back of the chair to recline while providing additional clearance. In other words, the forward movement associated with the projected pivot point allows the recliner to be placed closer to the wall than previously known mechanisms and chairs.BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Illustrative embodiments of the invention are described in detail below with reference to the attached drawing figures, and wherein:
[0009] FIG. 1 depicts a perspective view of a mechanism in the closed position, in accordance with aspects hereof;
[0010] FIG. 2 depicts a sectional view of the mechanism of FIG. 1, in accordance with aspects hereof;
[0011] FIG. 3 depicts a side elevation view of the mechanism of FIG. 1 in the closed position, in accordance with aspects hereof;
[0012] FIG. 4 is similar to FIG. 3, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof;
[0013] FIG. 5 depicts a perspective view of a mechanism in the TV position, in accordance with aspects hereof;
[0014] FIG. 6 depicts a sectional view of the mechanism of FIG. 5, in accordance with aspects hereof;
[0015] FIG. 7 depicts a side elevation view of the mechanism of FIG. 5 in the TV position, in accordance with aspects hereof;
[0016] FIG. 8 is similar to FIG. 7, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof;
[0017] FIG. 9 depicts a perspective view of a mechanism in the fully reclined position, in accordance with aspects hereof;
[0018] FIG. 10 depicts a sectional view of the mechanism of FIG. 9, in accordance with aspects hereof;
[0019] FIG. 11 depicts a side elevation view of the mechanism of FIG. 9 in the fully reclined position, in accordance with aspects hereof;
[0020] FIG. 12 is similar to FIG. 11, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof;
[0021] FIG. 13 depicts a partial perspective view of an alternative embodiment of a mechanism in the closed position, in accordance with aspects hereof;
[0022] FIG. 14 depicts an inner side elevation view of the mechanism of FIG. 13, in accordance with aspects hereof;
[0023] FIG. 15 depicts an outer side elevation view of the mechanism of FIG. 13 in the closed position, in accordance with aspects hereof;
[0024] FIG. 16 is similar to FIG. 15, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof;
[0025] FIG. 17 depicts a partial perspective view of the mechanism of FIG. 13 in the TV position, in accordance with aspects hereof;
[0026] FIG. 18 depicts an inner side elevation view of the mechanism of FIG. 17, in accordance with aspects hereof;
[0027] FIG. 19 depicts an outer side elevation view of the mechanism of FIG. 17 in the TV position, in accordance with aspects hereof;
[0028] FIG. 20 is similar to FIG. 19, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof;
[0029] FIG. 21 depicts a partial perspective view of the mechanism of FIG. 17 in the fully reclined position, in accordance with aspects hereof;
[0030] FIG. 22 depicts an inner side elevation view of the mechanism of FIG. 21, in accordance with aspects hereof;
[0031] FIG. 23 depicts an outer side elevation view of the mechanism of FIG. 21 in the fully reclined position, in accordance with aspects hereof;
[0032] FIG. 24 is similar to FIG. 23, but shown with the base plate hidden to reveal other links, in accordance with aspects hereof; and
[0033] FIG. 25 is a view of portions of the mechanism 210 in the fully reclined position overlaid on portions of the mechanism 210 in the closed position, and overlaid on a portion of a prior mechanism with a fixed pivot point.DETAILED DESCRIPTION
[0034] The subject matter of embodiments of the invention is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps, components, or combinations thereof, in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
[0035] Referring to the drawings, FIGS. 1-4 show a wood-to-the-floor recliner mechanism 10 in the closed position, FIGS. 5-8 show the mechanism 10 in the TV position, and FIGS. 9-12 show the recliner mechanism 10 in the fully reclined position. The mechanism 10 is a wood-to-the-floor mechanism, meaning that the sides of the chair on which the mechanism 10 is used do not have to extend to the floor to obscure the mechanism 10. This allows the chair to have a high-leg styling. In addition, and as more-fully described below, the mechanism 10 includes a back linkage that provides a projected back pivot point to reduce shirt pull, and moves the seat and the back forwardly to provide a chair that can be placed in close proximity to a wall (behind the chair) , while still allowing the full recline motion without interference from the wall.
[0036] Referring initially to FIGS. 1-4, the mechanism 10 of a recliner is shown in the closed position. The mechanism 10 couples together a footrest, chair back, chair arms and a chair seat of a recliner. One of skill in the art would understand the attachment of these chair components to the mechanism 10. For the sake of clarity, these portions of the chair are not shown. As a wood-to-the-floor mechanism, mechanism 10 includes a baseplate 12. The baseplate 12 is adapted to be coupled to the sides (or arms) of the chair, and may include slots 14 (see FIG. 3) for this purpose. The baseplate 12 supports the remainder of the mechanism 10 above the floor or other underlying surface. In some aspects, the baseplate 12 may also be coupled to the sides of the chair via a side bracket 16. The baseplate 12, in some aspects, also supports a rear motor tube 18 (see, e.g. FIG. 1) that is coupled to the base plate 12 via end brackets 20. As best seen in FIGS. 3 and FIG. 4, the mechanism 10 includes a rear travel linkage 22 coupled between the baseplate 12 and a trolley link 24. More specifically, the rear travel linkage 22 includes a pivot control link 26 pivotally coupled to the baseplate 12 at pivot point 28. The other end of the pivot control link 26 is pivotally coupled to a rear travel link 30 at pivot point 32 (generally at about a midpoint of the rear travel link 30) . The rear travel link 30 is a part of the rear travel linkage 22, and is also pivotally coupled to the trolley link 24 at pivot point 34 at the lower end of the rear travel link 30. In some aspects, and as seen in FIGS. 2 and 4, the rear travel link 30 may include a lower flange 36 that is used to couple a rear stabilizer tube 38 between opposing sides. The rear travel linkage 22 further includes a control link 40 that is pivotally coupled to the rear travel link 30 at pivot point 42. The end of the control link 40 opposite pivot point 42 is pivotally coupled to the base plate 12 at pivot point 44 (as seen in FIG. 3) . Through the rear travel linkage 22, the trolley link 24 is coupled to the baseplate 12.
[0037] The linkage mechanism 12 also includes a front travel linkage 46 that couples the trolley link 24 to the baseplate 12. The front travel linkage 46 includes a pivot control link 48, a front travel link 50 and a front toggle link 52. More specifically, the pivot control link 48 is pivotally coupled to the baseplate 12 at a pivot point 54. Opposite pivot point 54, the pivot control link 48 is pivotally coupled to the front travel link 50 at a pivot point 56 (generally about midway between the two ends of the front travel link 50) . The front travel link 50 is also pivotally coupled to the front toggle link 52 at a pivot point 58. Opposite pivot point 58, the front travel link 50 is pivotally coupled to the trolley link 24 at a pivot point 59. Opposite pivot point 58, the front toggle link 52 is pivotally coupled to the baseplate 12 at a pivot point 60. Through the front travel linkage 46, the trolley link 24 is pivotally coupled to the baseplate 12.
[0038] At the rear of the mechanism 10, as seen in FIG. 4, the trolley link 24 is pivotally coupled to a seat rail 62 via a rear pivot link 64. More specifically, the rear pivot link 64 is pivotally coupled on one end to the trolley link 24 at a pivot point 66. The rear pivot link 64 is also pivotally coupled to the seat rail 62 at a pivot point 68. Nearer the front of the mechanism 10, the trolley link 24 is pivotally coupled to the seat rail 62 via a front pivot link 70. More specifically, the front pivot link 70 is pivotally coupled on one end to the trolley link 24 at a pivot point 72. The front pivot link 70 is also pivotally coupled to the seat rail 62 at a pivot point 74.
[0039] The seat rail 62 and a back bracket 76 are coupled to the base plate 12, and are movably coupled to one another at the rear of the mechanism 10 through a back toggle 78, a back bellcrank 80 and a seat rail extension 82. More specifically, the back toggle 78 is pivotally coupled to the baseplate 12 at a pivot point 84. The end of the back toggle 78 opposite pivot point 84 is pivotally coupled to the back bellcrank 80 at a pivot point 86. The back bellcrank 80 is also pivotally coupled to the seat rail extension 82 at a pivot point 88. As seen in FIGS. 3 and 4, the seat rail extension 82 extends upwardly from the seat rail 62, and is fixedly coupled thereto. In practice, the seat rail 62 and the seat rail extension 82 could be a unitary piece. Further, the back bellcrank 80 is pivotally coupled to the back bracket 76 at a pivot point 90. The back bracket 76 is also pivotally coupled to the seat rail extension 82 via a back pivot 92. More specifically, the back pivot 92 is pivotally coupled to the seat rail extension 82 at a pivot point 94, and is pivotally coupled to the back bracket 76 at a pivot point 96. In this way, the back pivot 92 is an intermediate link that indirectly couples the seat rail 62 to the back bracket 76. By coupling the back bracket 76 to the seat rail 62 (via seat rail extension 82) and the baseplate 12 via the linkage of the back toggle 78 and the back bellcrank 80, and by coupling the back bracket 76 to the seat rail extension 82 via the back pivot 92, a projected pivot point 101 (see FIG. 8 and 12) , between an upholstered chair back and chair seat of the chair on which mechanism 210 is used, is created to provide better support in the fully reclined position, as well as reducing shirt pull when reclining. Moreover, this is accomplished using a compact linkage extending above the rear motor tube 18 and allowing a high leg styling, with the mechanism 10 hidden from view. The back bellcrank 80 and the back toggle 78 provide two shorter links than on previous mechanisms, allowing the pivotal connection of the back toggle 78 to the baseplate 12 to be generally horizontally aligned with the rear motor tube 18. As opposed to a metal-to-the-floor mechanism, the wood-to-the-floor mechanism 10 is compact, having a reduced mechanism height (see MH labeled in FIG. 4) . With this lower mechanism height, a chair having a high-leg styling may be achieved, along with the benefits of better lumbar support, reduced shirt pull, and allowing a close-to-the-wall proximity chair. The two-link coupling of the back toggle 78 and the back bellcrank 80 between the back bracket 76, the seat plate extension 82 and the baseplate 12 (along with the back pivot 92) creates the projected pivot point 101, while at the same time allowing a compact mechanism height. As best seen in FIG. 3, the pivot point 84 is located forwardly and above the pivotal connection of the motor 152 to the rear motor tube 18. As can also be seen in the figures, the pivot point 88 remains behind pivot point 90 as the mechanism 10 moves between the closed, TV and recline positions. Moreover, as best seen by comparing FIGS. 3, 7 and 11, if a vertical line is passed through pivot points 88 and 90, it can be seen that the vertical lines drawn through pivot points 88 and 90 would be closer together in the closed and TV positions, and farther apart in the fully reclined position. As can also be seen, pivot point 94 is forward of pivot point 96 in the closed and TV positions, but pivot point 94 is rearward of pivot point 96 in the fully reclined position.
[0040] The mechanism 10 also includes an ottoman linkage 100, as seen in FIG. 8. The ottoman linkage 100 include a front ottoman link 102 pivotally coupled to the seat rail 62 at a pivot point 104 and a rear ottoman link 106 pivotally coupled to the seat rail 62 at a pivot point 108. The front ottoman link 102 is also pivotally coupled to an outside ottoman link 110 at a pivot point 112, and to an inside ottoman link 114 at a pivot point 116. The outside ottoman link 110 is also pivotally coupled to the rear ottoman link 106 at a pivot point 118. The ottoman linkage 100 further includes a mid-ottoman bracket 120 that is pivotally coupled to the outside ottoman link 110 at a pivot point 122. The mid-ottoman bracket 120 is also pivotally coupled to a mid-ottoman control link 126 at a pivot point 128. The end of the mid-ottoman control link 126 opposite pivot point 128 is pivotally coupled to the inside ottoman link 114 at a pivot point 130. An ottoman bracket 132 is pivotally coupled to the end of the outside ottoman link 110 opposite pivot point 118, at a pivot point 134. The ottoman bracket 132 is also pivotally coupled to the inside ottoman link 114 at a pivot point 136. And then, a flipper ottoman bracket 138 is pivotally coupled at the end of the inside ottoman link 114 opposite pivot point 116, at a pivot point 140. The flipper ottoman bracket 138 is coupled to the ottoman bracket 132 via a flipper control link 142. More specifically, the flipper control link 142 is pivotally coupled to the flipper ottoman bracket 138 at a pivot point 144 and is pivotally coupled to the ottoman bracket 132 at a pivot point 146.
[0041] As seen in FIG. 6, a front motor tube 150 is fixedly coupled to the front ottoman link 102, and extends between opposing front ottoman links 102. A motor 152 is pivotally coupled to the front motor tube 150, generally mid-way along the front motor tube 150. The motor 152 extends between the front motor tube 150 and the rear motor tube 18 (and is pivotally coupled to the rear motor tube 18) . As seen in FIG. 6, in some aspects, a stabilizer tube 154 may be coupled to each trolley link 24, such that the stabilizer tube 154 extends between opposing trolley links 24. Further, an ottoman drive link 156 extends between the rear ottoman link 106 and the rear pivot link 64. More specifically, the ottoman drive link 156 is pivotally coupled to the rear ottoman link 106 at a pivot point 158 on one end, and is pivotally coupled to the rear pivot link 64 at a pivot point 160 on the other end.
[0042] The mechanism 10 may move between the closed position of FIGS. 1-4, to the TV position of FIGS. 5-8, to the fully reclined position of FIGS. 9-12 through operation of the motor 152. As discussed above, the mechanism 10 provides a projected pivot point for the chair back that is close to the point at which the bottom of a chair back cushion and the back of a seat cushion meet, when in a finished chair. In styling a finished chair, the manufacturer can design the chair back and seat such that they meet as close to the projected pivot point as possible. Additionally, a finished chair having the above described mechanism 10 requires less wall clearance than typical recliners because of the forward movement gained from having the back bracket 76 rotate about the projected pivot point and as opposed to the typical direct coupling of the back bracket to the seat mounting plate. Indeed, the above described recline mechanism provides a reduced wall clearance below what was previously thought possible, while at the same time providing a wood-to-the-floor mechanism allowing high-leg styling. The coupling between the seat rail 62 and the back bracket 76, through the two shorter, pivotally coupled, back toggle 78 and back bellcrank 80 (along with the back pivot 92) , allow an indirect coupling of the back bracket 76 to the seat rail extension 82, which provides a projected back pivot in a compact mechanism usable on high-leg styling.
[0043] In the embodiment of FIGS. 1-12, the back bellcrank 80 and the back toggle 78 control the movement of the back bracket 76 (and thus the back coupled to the back bracket 76) , supported also by the back pivot 92. For some users, the movement of the back using mechanism 10 in going from the TV position of FIGS. 5-8 to the fully reclined position of FIGS. 9-12 feels a little faster than they may like, especially in the latter stages of rotation. To slow, or better control, the rotation of the back bracket (and thus the back) as the mechanism moves from the TV position to the fully reclined position, as well as to achieve farther forward movement of the back bracket (to allow the chair to be operational even closer to a wall) , an additional embodiment is shown in FIGS. 13-24. Although many of the components are the same, or at least similar, a complete description is provided below.
[0044] FIGS. 13-16 show a wood-to-the-floor recliner mechanism 210 in the closed position, FIGS. 17-20 show the mechanism 210 in the TV position, and FIGS. 21-24 show the recliner mechanism 210 in the fully reclined position. The mechanism 210 is a wood-to-the-floor mechanism, meaning that the sides of the chair on which the mechanism 210 is used do not have to extend to the floor to obscure the mechanism 210. This allows the chair to have a high-leg styling. In addition, and as more-fully described below, the mechanism 210 includes a back linkage that provides a projected back pivot point to reduce shirt pull, and moves the seat and the back forwardly to provide a chair that can be placed in close proximity to a wall (behind the chair) , while still allowing the full recline motion without interference from the wall.
[0045] Referring initially to FIGS. 13-16, the mechanism 210 of a recliner is shown in the closed position. The mechanism 210 couples together a footrest, chair back, chair arms and a chair seat of a recliner. One of skill in the art would understand the attachment of these chair components to the mechanism 210. For the sake of clarity, these portions of the chair are not shown. As a wood-to-the-floor mechanism, mechanism 210 includes a baseplate 212. The baseplate 212 is adapted to be coupled to the sides (or arms) of the chair, and may include slots 214 (see FIG. 15) for this purpose. The baseplate 212 supports the remainder of the mechanism 210 above the floor or other underlying surface. In some aspects, the baseplate 212 may also be coupled to the sides of the chair via a side bracket 216. The baseplate 212, in some aspects, also supports a rear motor tube 218 (see, e.g. FIG. 13) that is coupled to the base plate 212 via end brackets 220. As best seen in FIGS. 15, 16 and FIG. 20, the mechanism 210 includes a rear travel linkage 222 coupled between the baseplate 212 and a trolley link 224. More specifically, the rear travel linkage 222 includes a pivot control link 226 pivotally coupled to the baseplate 212 at pivot point 228. The other end of the pivot control link 226 is pivotally coupled to a rear travel link 230 at pivot point 232 (generally at about a midpoint of the rear travel link 230) . The rear travel link 230 is a part of the rear travel linkage 222, and is also pivotally coupled to the trolley link 224 at pivot point 234 at the lower end of the rear travel link 230. In some aspects, and as seen in FIGS. 13 and 17, the rear travel link 230 may include a lower flange 236 that is used to couple a rear stabilizer tube (not shown but similar to rear stabilizer tube 38 in FIGS. 1-12) between opposing sides. The rear travel linkage 222 further includes a control link 240 that is pivotally coupled to the rear travel link 230 at pivot point 242. The end of the control link 240 opposite pivot point 242 is pivotally coupled to the base plate 212 at pivot point 244 (as seen in FIG. 15) . Through the rear travel linkage 222, the trolley link 224 is coupled to the baseplate 212.
[0046] As seen in FIG. 16, the linkage mechanism 210 also includes a front travel linkage 246 that couples the trolley link 224 to the baseplate 212. The front travel linkage 246 includes a pivot control link 248, a front travel link 250 and a front toggle link 252. More specifically, the pivot control link 248 is pivotally coupled to the baseplate 212 at a pivot point 254. Opposite pivot point 254, the pivot control link 248 is pivotally coupled to the front travel link 250 at a pivot point 256 (generally about midway between the two ends of the front travel link 250) . The front travel link 250 is also pivotally coupled to the front toggle link 252 at a pivot point 258. Opposite pivot point 258, the front travel link 250 is pivotally coupled to the trolley link 224 at a pivot point 259. Opposite pivot point 258, the front toggle link 252 is pivotally coupled to the baseplate 212 at a pivot point 260. Through the front travel linkage 246, the trolley link 224 is pivotally coupled to the baseplate 212.
[0047] At the rear of the mechanism 210, as seen in FIG. 14, the trolley link 224 is pivotally coupled to a seat rail 262 via a rear pivot link 264. More specifically, the rear pivot link 264 is pivotally coupled on one end to the trolley link 224 at a pivot point 266. The rear pivot link 264 is also pivotally coupled to the seat rail 262 at a pivot point 268. As seen in FIG. 16, nearer the front of the mechanism 210, the trolley link 224 is pivotally coupled to the seat rail 262 via a front pivot link 270. More specifically, the front pivot link 270 is pivotally coupled on one end to the trolley link 224 at a pivot point 272. The front pivot link 270 is also pivotally coupled to the seat rail 262 at a pivot point 274.
[0048] The seat rail 262 and a back bracket 276 are coupled to the base plate 212, and are movably coupled to one another at the rear of the mechanism 212 through a back toggle 278, a back bellcrank 280 and a seat rail extension 282. More specifically, the back toggle 278 is pivotally coupled to the baseplate 212 at a pivot point 284, which, in some aspects, is located slightly below, and behind, the comparable pivot point 84 in FIGS. 1-12. The end of the back toggle 278 opposite pivot point 284 is pivotally coupled to the back bellcrank 280 at a pivot point 286. The back bellcrank 280 is also pivotally coupled to the seat rail extension 282 at a pivot point 288. As seen in FIGS. 15 and 16, the seat rail extension 282 extends upwardly from the seat rail 262, and is fixedly coupled thereto. The seat rail extension 282 may be shaped somewhat differently than seat rail extension 82, with the pivot point 288 being more rearward than the comparable pivot point 88 in FIGS. 1-12. In practice, the seat rail 262 and the seat rail extension 282 could be a unitary piece. Unlike the embodiment in FIGS. 1-12, the back bellcrank 280 is not directly pivotally coupled to the back bracket 276. Rather, a rear back pivot link 290 is pivotally coupled to the back bracket 276 at a pivot point 289. The opposite end of the rear back pivot link 290 is pivotally coupled to the back bellcrank 280 at a pivot point 291. As can be seen by comparing FIG. 3 to FIG. 15, the pivot point 289 is moved upwardly relative to pivot point 90 to accommodate other components, as discussed further below. The back bracket 276 is also pivotally coupled to the seat rail extension 282 via a back pivot 292. More specifically, the back pivot 292 is pivotally coupled to the seat rail extension 282 at a pivot point 294, and is pivotally coupled to the back bracket 276 at a pivot point 296. In some aspects, the back pivot 292 has a slight bend, such that pivot point 296 is more rearward that pivot point 294 (in the closed position) . In this way, the back pivot 292 is an intermediate link that indirectly couples the seat rail 262 (through seat rail extension 282) to the back bracket 276. Additionally, in the embodiment of FIGS. 13-24, a connector link 297 is pivotally coupled between the back pivot 292 and the back bellcrank 280. More specifically, the connector link 297 is pivotally coupled to the back pivot 292 at a pivot point 298 and is pivotally coupled to the back bellcrank 280 at a pivot point 299. In this way, the back bellcrank 280 is directly pivotally coupled to the rear back pivot link 290 (at pivot point 291) and to the seat rail extension 280 (at pivot point 288) . The back bellcrank 280 is also indirectly coupled to the back bracket 276 through the back pivot 292 (through the connector link 297) and the rear back pivot link 290.
[0049] By coupling the back bracket 276 to the seat rail 262 (via seat rail extension 282) and the baseplate 212 via the linkage of the back toggle 278, the back bellcrank 280, and the rear back pivot link 290; and by coupling the back bracket 276 to the seat rail extension 282 via the back pivot 292, a projected pivot point 400 (see FIG. 18 and 22) between an upholstered chair back and chair seat of the chair on which mechanism 210 is used is created to provide better support in the fully reclined position, as well as reducing shirt pull when reclining. The back bellcrank 280 and the back toggle 278 provide two shorter links than on previous mechanisms, allowing the pivotal connection of the back toggle 278 to the baseplate 212 to be generally horizontally aligned with the rear motor tube (and well above an underlying support surface, allowing a high-leg styling) . In the embodiment of FIGS. 13-24, the movement of the back bracket 276 is controlled via the back pivot 292 and the rear back pivot link 290 as the back bellcrank 280 rotates through the direct coupling of the back bellcrank 280 to the rear back pivot link 290, and through the indirect coupling of the back pivot 292 to the back bellcrank 280 through the connector link 297. It has been found that this linkage provides a better feel for some users as the back bracket 276 rotates from the TV position to the fully reclined position. As with the embodiment of FIGS. 1-12, this is accomplished using a compact linkage extending above the rear motor tube 218 and allowing a high leg styling, with the mechanism 210 hidden from view. As opposed to a metal-to-the-floor mechanism, the wood-to-the-floor mechanism 210 must be compact, having a reduced mechanism height (see MH labeled in FIG. 15) . With this lower mechanism height, a chair having a high-leg styling may be achieved, along with the benefits of better lumbar support, reduced shirt pull, and allowing a close-to-the-wall proximity chair.
[0050] FIG. 25 shows portions of the mechanism 210 in the fully reclined position overlaid on portions of the mechanism 210 in the closed position. FIG. 25 also shows the location of a prior seat plate extension 500 and a prior fixed pivot point 502 for context. As can be seen, the back bracket 276 moves forwardly, and downwardly (compare 276 to 276’) as the mechanism 210 moves from the closed position to the fully reclined position. The pivot point 296 moves forwardly (compare pivot point 296 to pivot point 296’) a distance (labeled “D” in FIG. 25) . This distance is greater than on previously known mechanisms, allowing the chair back on which mechanism 210 is used to be placed even closer to an adjacent wall, while still allowing unobstructed movement to the fully reclined position. For example, the distance D can be greater than 2.25 inches. In some aspects, the distance D is in the range of between about 2.5 and 4 inches. In some aspects, the distance D is about 3.25 inches.
[0051] The three-link coupling of the back toggle 278, the back bellcrank 280 and the rear back pivot link 290 between the back bracket 276, the seat plate extension 282 and the baseplate 212 (along with the back pivot 292 and the connector link 297) allows the pivot point of the seat and back to be projected forward and upward (at point 400, for example) to reduce shirt pull and provide lumbar support while reclining, while at the same time allowing a compact mechanism height. As best seen in FIG. 15, the pivot point 284 is located forwardly and slightly above the pivot point connection 251of a motor (not shown in FIGS. 13-24 but the motor is similar to that shown in FIGS. 1-12) to the rear motor tube 218. As can also be seen in the figures, the pivot point 288 remains behind pivot point 289 as the mechanism 210 moves between the closed, TV and recline positions. Moreover, as best seen by comparing FIGS. 15, 19 and 23, if a vertical line is passed through pivot points 288 and 289, it can be seen that the vertical lines drawn through pivot points 288 and 289 would be closer together in the closed and TV positions, and farther apart in the fully reclined position. As can also be seen, pivot point 294 is forward of pivot point 296 in the closed and TV positions, but pivot point 294 is rearward of pivot point 296 in the fully reclined position.
[0052] As with the mechanism 10, the mechanism 210 also includes an ottoman linkage 300, as seen in FIG. 20. The ottoman linkage 300 include a front ottoman link 302 pivotally coupled to the seat rail 262 at a pivot point 304 and a rear ottoman link 306 pivotally coupled to the seat rail 262 at a pivot point 308. The front ottoman link 302 is also pivotally coupled to an outside ottoman link 310 at a pivot point 312, and to an inside ottoman link 314 at a pivot point 316. The outside ottoman link 310 is also pivotally coupled to the rear ottoman link 306 at a pivot point 318. The ottoman linkage 300 further includes a mid-ottoman bracket 320 that is pivotally coupled to the outside ottoman link 310 at a pivot point 322. The mid-ottoman bracket 320 is also pivotally coupled to a mid-ottoman control link 326 at a pivot point 328. The end of the mid-ottoman control link 326 opposite pivot point 328 is pivotally coupled to the inside ottoman link 314 at a pivot point 330. An ottoman bracket 332 is pivotally coupled to the end of the outside ottoman link 310 opposite pivot point 318, at a pivot point 334. The ottoman bracket 332 is also pivotally coupled to the inside ottoman link 314 at a pivot point 336. And then, a flipper ottoman bracket 338 is pivotally coupled at the end of the inside ottoman link 314 opposite pivot point 316, at a pivot point 340. The flipper ottoman bracket 338 is coupled to the ottoman bracket 332 via a flipper control link 342. More specifically, the flipper control link 342 is pivotally coupled to the flipper ottoman bracket 338 at a pivot point 344 and is pivotally coupled to the ottoman bracket 332 at a pivot point 346.
[0053] As seen in FIG. 18, a front motor tube 350 is fixedly coupled to the front ottoman link 302, and extends between opposing front ottoman links 302. A motor (not shown but similar to motor 152 of FIGS. 13-24) is pivotally coupled to the front motor tube 350, generally mid-way along the front motor tube 350. The motor extends between the front motor tube 350 and the rear motor tube 218 (and is pivotally coupled to the rear motor tube 218) . As seen in FIG. 18, in some aspects, a stabilizer tube may be coupled to each trolley link 224 via a bracket 354, allowing a stabilizer tube (similar to stabilizer tube 154 of FIGS. 1-12) to extend between opposing trolley links 224. Further, an ottoman drive link 356 extends between the rear ottoman link 306 and the rear pivot link 264. More specifically, the ottoman drive link 356 is pivotally coupled to the rear ottoman link 306 at a pivot point 358 on one end, and is pivotally coupled to the rear pivot link 264 at a pivot point 360 on the other end. As seen in FIG. 13, a spring bracket 370 may be affixed to the rear motor tube 218, extending downwardly therefrom. And, a spring retainer pin 372 may be affixed to the rear pivot link 264, extending inwardly. While not shown, an extension spring may be installed, extending between the spring bracket 370 and the pin 372. The spring operates to assist in moving from the fully reclined position to the TV position. Further, in some aspects, a similar spring-assist arrangement may also be used in the embodiment of FIGS. 1-12.
[0054] The mechanism 210 may move between the closed position of FIGS. 13-16, to the TV position of FIGS. 17-20, to the fully reclined position of FIGS. 21-24 through operation of the motor. As discussed above, the mechanism 210 provides a projected pivot point for the chair back that is close to the point at which the bottom of a chair back cushion and the back of a seat cushion meet, when in a finished chair. In styling a finished chair, the manufacturer can design the chair back and seat such that they meet as close to the projected pivot point as possible. As a result of the projected pivot point being forward of the back bracket 276, the back bracket 276 swings forward as the chair reclines to the TV position and moves forward again as the chair reclines to the fully reclined position. Thus, a finished chair having the above described recline mechanism requires less wall clearance than typical recliners because of the forward movement gained from having the back bracket 276 rotate about the projected pivot point and as opposed to the typical direct coupling of the back bracket to the seat mounting plate. Indeed, the above described recline mechanism provides a reduced wall clearance below what was previously thought possible, while at the same time providing a wood-to-the-floor mechanism allowing high-leg styling. The coupling between the seat rail 262 and the back bracket 276, through the three shorter, pivotally coupled links (back toggle 278, back bellcrank 280, and rear back pivot link 290) , along with the back pivot 292 and the connector link 297, allow an indirect coupling of the back bracket 276 to the seat rail extension 282, which provides a projected back pivot in a compact mechanism usable on high-leg styling.
[0055] Many different arrangements of the various components depicted, as well as components not shown, are possible. Embodiments of the technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.
Claims
1.A compact linkage mechanism for a wood-to-the-floor seating unit, comprising:a baseplate adapted to be coupled to a side frame of the seating unit, the baseplate suspended above a support surface of the seating unit when coupled to the seating unit;a seat rail for mounting a seat of the seating unit;a seat rail extension coupled to the seat rail, the seat rail extension having a first pivot point for pivotal connection to a back pivot link;the back pivot link having a first end opposite a second end, wherein the first end of the back pivot link is pivotally connected to the seat rail extension at the first pivot point;a back bracket for mounting a back of the seating unit, the back bracket having a forward pivot point, wherein the second end of the back pivot link is pivotally connected to the back bracket at the forward pivot point; anda back bellcrank pivotally coupled to the seat rail extension at a third pivot point rearward of the first pivot point, the back bellcrank also being pivotally coupled to the back bracket at a fourth pivot point rearward of the forward pivot point, the back bellcrank being pivotally coupled to the baseplate;wherein upon forward motion of the seat mounting plate as the linkage mechanism unfolds from a closed position to a fully reclined position the forward pivot point is moved forwardly and downwardly.2.The linkage mechanism of claim 1, further comprising:a back toggle pivotally coupled on one end to the baseplate and on the other end to the back bellcrank;wherein the back bellcrank is indirectly pivotally coupled to the baseplate.3.A compact linkage mechanism for a wood-to-the-floor seating unit, comprising:a baseplate adapted to be coupled to a side frame of the seating unit, the baseplate suspended above a support surface of the seating unit when coupled to the seating unit;a seat rail for mounting a seat of the seating unit;a seat rail extension coupled to the seat rail, the seat rail extension having a first pivot point for pivotal connection to a back pivot link;the back pivot link having a first end opposite a second end, wherein the first end of the back pivot link is pivotally connected to the seat rail extension at the first pivot point;a back bracket for mounting a back of the seating unit, the back bracket having a forward pivot point, wherein the second end of the back pivot link is pivotally connected to the back bracket at the forward pivot point; anda back bellcrank pivotally coupled to the seat rail extension at a third pivot point rearward of the first pivot point, the back bellcrank also being indirectly pivotally coupled to the back bracket and the baseplate;wherein upon forward motion of the seat mounting plate as the linkage mechanism unfolds from a closed position to a fully reclined position the forward pivot point is moved forwardly and downwardly.4.The linkage mechanism of claim 3, further comprising a rear back pivot link pivotally coupled on a first end to the back bracket and pivotally coupled on a second end to the back bellcrank.5.The linkage mechanism of claim 4, further comprising a connector link pivotally coupled on a first end to the back pivot link and pivotally coupled on a second end to the back bellcrank, the connector link extending between the back bellcrank and the back pivot link.6.The linkage mechanism of claim 5, further comprising:a back toggle pivotally coupled on one end to the baseplate and on the other end to the back bellcrank;wherein the back bellcrank is indirectly pivotally coupled to the baseplate.7.The linkage mechanism of claim 6, whereupon movement of the linkage mechanism from the closed position to the fully reclined position, the back bracket rotates around a projected pivot point.8.The linkage mechanism of claim 7, wherein the projected pivot point is forward and above the forward pivot point of the back bracket when the linkage mechanism is in the closed position.