Zero-Wall Clearance Linkage for Compact Recliner Motion Sequencing
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Solution Overview
Problem
Conventional motion upholstery furniture linkage mechanisms are complex, limiting design flexibility, requiring multiple motors for full motion adjustment, occupying more space, and prone to tipping and sequence errors during motorized adjustments.
Innovation Solution
A simplified linkage mechanism allowing a compact motor to achieve full movement and sequenced adjustment between closed, extended, and reclined positions, with features like a rear bellcrank and sequence plate to prevent tipping and sequence errors, and a rotation-limiting mechanism for space-saving zero-wall clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional complex linkage mechanisms are used, then full motion adjustment capability is achieved, but device complexity increases and multiple motors are required
Solution Approach 1:
The linkage mechanism is divided into separate functional modules: a first linkage module controlling footrest extension/retraction and a second linkage module controlling backrest recline. Each module has its own motor, allowing independent control and simplifying the overall system architecture while maintaining full motion adjustment capability.
Solution Approach 2:
Each motorized linkage module is designed to perform multiple functions: the first motorized linkage module handles both footrest extension and recline initiation, while the second motorized linkage module handles backrest recline and position maintenance, reducing the need for dedicated mechanisms for each motion.
2Adaptability or versatility
If conventional linkage mechanisms are used, then motion adjustment is achieved, but space occupied increases requiring wall clearance
Solution Approach 1:
The linkage mechanism incorporates vertical movement components that allow the footrest and backrest to adjust in multiple dimensions. The footrest can extend forward and upward, while the backrest can recline backward and upward, utilizing vertical space to reduce horizontal clearance requirements for wall proximity.
Solution Approach 2:
The linkage components are arranged in a nested configuration where the footrest linkage is positioned within or adjacent to the backrest linkage structure. This compact arrangement minimizes the overall footprint and allows the seating unit to be placed closer to walls by utilizing overlapping spatial paths of the linkage components.
3Extent of automation
If motorized adjustment is used with conventional mechanisms, then automation is achieved, but tipping occurs during adjustment
Solution Approach 1:
The linkage mechanism incorporates counterbalancing elements that offset the weight of moving components during adjustment. The first motorized linkage module includes counterbalancing for the footrest assembly, and the second motorized linkage module includes counterbalancing for the backrest, preventing tipping by compensating for gravitational forces during motorized adjustment.
Solution Approach 2:
The motorized linkage system incorporates feedback mechanisms that monitor the position and load during adjustment. The control system receives feedback from sensors detecting the state of the footrest and backrest linkages, allowing real-time adjustment of motor torque and speed to maintain stability and prevent tipping during automated adjustment sequences.
4Extent of automation
If conventional linkage mechanisms are used, then motion adjustment is achieved, but sequence errors occur during motorized adjustment
Solution Approach 1:
The control system is programmed with predetermined adjustment sequences that execute motions in the correct order. Before initiating full recline, the system first extends the footrest to the desired position, then initiates backrest recline. This preliminary sequencing ensures that components are positioned in the correct order, preventing sequence errors during motorized adjustment.
Solution Approach 2:
Sensors monitor the position of the footrest and backrest linkages throughout adjustment, providing feedback to the control system. When the footrest reaches its extended position, the feedback signal triggers the next phase of the sequence (backrest recline). This feedback-based sequencing ensures accurate execution of the adjustment sequence and prevents errors by waiting for proper positioning before initiating subsequent motions.
Data Source
AI summary
A seating unit that includes a linkage mechanism adapted to adjust between closed, extended, and reclined positions is provided. The linkage mechanism includes a seat-mounting plate mounted to a footrest assembly, a back-mounting link and a rear bellcrank both rotatably coupled to the seat-mounting plate, an activator bar that controls a footrest drive link, and a linear actuator for carrying out automated adjustment of the linkage assembly. In operation, a stroke in a first phase of the linear actuator generates a torque on the activator bar. The footrest drive link converts the torque into a laterally-directed force that pushes the footrest assembly into the extended position. A stroke in the second phase acts to push the activator bar forward and translate the seat-mounting plate forward at a consistent inclination angle. The forward translation causes the rear bellcrank to rotate, thereby biasing the back-mounting link rearward into the reclined position.