CN110811193B - Zero wall clearance linkage for providing additional layout - Google Patents

Abstract

The invention relates to a zero wall clearance linkage for providing additional layout. There is provided a seating apparatus for facilitating recline and tilt of a backrest, the seating apparatus comprising: a substrate; a rear pivot link; a rear bell crank; a rear control link; a lap joint connecting rod; a front lifting connecting rod; a front pivot link; a bracket link; and a front bell crank, wherein the bracket link includes a first pivot attaching a front portion of the bracket link to the front pivot link and a second pivot attaching a rear portion of the bracket link to the front bell crank, and wherein a distance between the first pivot and the second pivot is greater than or equal to about 8 inches and less than or equal to about 8.6 inches.

Description

Zero wall clearance linkage for providing additional layout

The present application is a divisional application of the inventive patent application with the application date of 2014, 10, 28, 201480006053.2 and the invention name of "zero wall clearance linkage for providing additional layout".

Technical Field

The present invention relates generally to movable upholstered furniture designed to support a user's body in a substantially fixed position. Movable upholstered furniture including lounges, reclining chairs, sofas, twin sofas, sectional sofas, theatre seating positions, conventional seats, and seats having movable seating portions are generally referred to herein as "seating units". More particularly, the present invention relates to developing an improved linkage for accommodating a wide variety of seating units, otherwise the seating units in the art are defined by the configuration of the linkage. Furthermore, the improved linkage of the present invention allows a seating unit placed against a wall or near another stationary object to recline.

Background

There are reclining seating units that allow a user to extend a footrest forward and recline a back with respect to a seat. These existing seating units typically provide three basic positions (e.g., a standard, non-reclined closed position; an extended position; and a reclined position). In the closed position, the seat is in a generally horizontal orientation and the backrest is disposed substantially upright. Furthermore, if the seating unit includes one or more stools (ottomans) to which the mechanism is attached, the mechanism is folded so that the stools do not extend. In an extended position, commonly referred to as a television ("TV") position, the bench extends in front of the seat, while the back rest is still sufficiently upright to allow a user of the seating unit to comfortably view television. In the reclined position, the back pivots rearwardly from the extended position to an obtuse relationship with the seat for rest or sleep.

Several modern seating units in the industry are adapted to provide the adjustment capability described above. However, these seating units require relatively complex linkages to afford this capability. When combined with automation, complex linkage assemblies can limit certain design links. In particular, these linkage assemblies have limitations in incorporating a single motor for automating the adjustment between the positions described above, and two or more motors are required to accomplish the automation of each adjustment. For example, achieving full range motion when automatically adjusting between multiple positions typically requires multiple large motors, each with a large stroke. (the geometry of the linkage assembly prevents a single large motor from being mounted thereon without interfering with the cross beam, underlying surface, or moving parts attached to the linkage assembly.) thus, a more accurate linkage mechanism that can achieve omni-directional movement will fill the gap in the prior art in the field of mobile decoration when automatically adjusted between the closed, extended, and reclined positions.

Furthermore, the lack of lateral adjustment provided by conventional complex linkages disadvantageously requires the entire seat unit to be moved outwardly away from the adjacent wall. Thus, the conventional complex linkages require the seating unit to occupy a larger floor space. Otherwise, the backrest in the reclined position will be in contact with the adjacent wall without providing a substantial gap between the backrest and the adjacent wall.

Furthermore, when motorized adjustments are employed to conventional complex linkages, the seating units housing these mechanisms are prone to tipping forward when adjusted to the reclined position. Tipping is typically caused by a user of the seating unit leaning forward and the motor or other automated mechanism not allowing the folding of the footrest assembly holding the stool outward from the seating unit. Accordingly, the user typically must make motorized adjustments when tilting forward in the seat unit to avoid the seat unit from tipping over.

Furthermore, motorized adjustment of conventional complex linkages often results in out-of-order movement of the stool and backrest of the seating unit. For example, when adjusted from a closed position to an extended position, pressure on the stool by the user's legs may cause resistance to extending the footrest assembly. As a result of this resistance, motorized adjustment may begin to recline the back out of sequence until a complete travel of the predetermined travel is obtained.

Accordingly, embodiments of the present invention relate to a novel linkage that allows a seating unit to provide space-saving utility that compensates for the need for substantial wall clearance. Furthermore, the linkage of the present invention is constructed in a simple and accurate arrangement to provide the proper function while compensating for the above-described undesirable features inherent in conventional complex linkages.

Disclosure of Invention

Embodiments of the present invention seek to provide a simplified linkage mechanism that can be assembled to a single compact motor and can be adapted to substantially any type of seating unit. In one exemplary embodiment, the compact motor and linkage may collectively effect all-round movement and sequential adjustment of the seating unit between the closed position, the extended position, and the reclined position. The compact motor can adjust the linkage in a skilled, low cost manner without creating interference in conventional automated designs or other internal drawbacks inherent to automation. The linkage may be configured to have the function of helping to prevent tipping of the seating unit, sequential adjustment of the seating unit between positions, locking the footrest assembly in the extended position, and correcting other drawbacks that occur in conventional designs. Various drive link configurations may be utilized, such as a single drive link or a multiple drive link assembly.

Generally, the novel seating unit includes the following components: first and second leg rest (support leg) stools; a pair of substrates in a substantially parallel spaced apart relationship; a pair of seat mounting plates in a substantially parallel spaced apart relationship; a seat support surface extending between the seat mounting plates; and a pair of generally mirror-image linkages interconnecting the base plate and the seat-mounting plate. Further, the seat mounting plate is arranged in an oblique direction with respect to a surface of a lower layer of the seat unit. In operation, the linkage is adapted to move between a closed position, an extended position, and a reclined position.

Typically, the linkage includes a pair of footrest assemblies that movably interconnect the first and second footrests to the seat-mounting plate. In an embodiment, the linkages each include a seat adjustment assembly with a rear bell crank adapted to translate the respective seat mounting plates on the base plate during adjustment between the closed position, the extended position, and the reclined position. In an embodiment, the rear bell crank translates the seat-mounting plates while maintaining the seat-mounting plates in an inclined orientation with the base plate. Thus, the seat support surface may be biased at a particular angle of inclination throughout the adjustment process.

In another embodiment, each linkage includes a sequence adjustment plate and a sequence adjustment element. The sequence adjustment plate includes a guide groove configured to have a first region, a second region, and an intermediate region interconnecting the first region and the second region. The sequence adjustment element typically extends into the guide slot. In operation, the sequencing element is still within the first region when the seat unit is adjusted between the extended position and the reclined position, is still within the intermediate region when the seat unit is adjusted to the extended position, and is still within the second region when the seat unit is adjusted between the extended position and the closed position. Thus, the backrest is constrained to inadvertently recline when moving from the closed position to the extended position. In addition, the footrest assembly is restrained from inadvertently folding or closing when moving from the reclined position to the extended position.

In yet another embodiment, the rotation limiting mechanism helps limit the tilt and recline of the linkage. For example, the rotation limiting mechanism facilitates forward rotation of the back of the seat unit when the linkage is in the closed position and the seat unit is in the upright position. In addition, the rotation limiting mechanism also helps support the linkage when the linkage is opened to the fully reclined position. An exemplary rotation limiting mechanism includes a stop element secured to a position on the linkage to limit a range of motion of one or more links of the linkage.

Drawings

In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith, like reference numerals are used to designate like parts in the different views:

FIG. 1 is a side view of a portion of a seating unit in a closed position, according to one embodiment of the present invention;

FIG. 2 is a view similar to FIG. 1 but in an extended position in accordance with one embodiment of the present invention;

FIG. 3 is a view similar to FIG. 1 but in a reclined position in accordance with an embodiment of the present invention;

FIG. 4 is a perspective view of a linkage mechanism in a reclined position according to one embodiment of the present invention;

FIG. 5 is a diagrammatic side view of the linkage mechanism in a reclined position, as seen from a vantage point within the seating unit, in accordance with an embodiment of the present invention;

FIG. 6 is a view similar to FIG. 5 but in an extended position in accordance with one embodiment of the present invention;

FIG. 7 is a view similar to FIG. 5 but in a closed position in accordance with one embodiment of the invention;

8A-8D illustrate different views of a linkage mechanism including a linear actuator including two drive links and providing motorized adjustment of a seating unit, according to one embodiment of the present invention;

FIG. 9 is a diagrammatic side view of a linkage mechanism adjusted to be in a reclined position in an extended state of the tilt mechanism in accordance with an embodiment of the present invention;

FIG. 10 is a view similar to FIG. 9 but in an extended position with the anti-tipping mechanism retracted, in accordance with one embodiment of the invention;

FIG. 11 is a diagrammatic side view of the linkage mechanism in a reclined position from a vantage point external to the seating unit, in accordance with an embodiment of the present invention;

FIG. 12 is a partial side view of the linkage mechanism in a closed position highlighting the sequence adjustment plate according to one embodiment of the present invention;

FIG. 13 is a view similar to FIG. 12 but in an extended position in accordance with one embodiment of the present invention;

FIG. 14 is a view similar to FIG. 12 but in a reclined position in accordance with an embodiment of the present invention;

FIG. 15 is a diagrammatic perspective view of a substrate having a molding step at one end in accordance with an embodiment of the present invention;

FIG. 16 is a diagrammatic side view of a sequence adjustment plate detached from a linkage according to one embodiment of the invention;

17A-17C illustrate a linkage having members of different geometries similar to FIGS. 4-7 in accordance with one embodiment of the invention; and

Fig. 18A-18D illustrate an alternative form of linear actuator that includes a single drive link and provides motorized adjustment of the seating unit in accordance with one embodiment of the present invention.

Detailed Description

The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements. The description itself is not intended to necessarily limit the scope of the claims. Rather, the claimed subject matter may be implemented in other ways to include different elements or combinations of elements similar to the ones described in this document in conjunction with other prior art or future technologies.

Fig. 1-3 show a portion of a seating unit 10, which is shown in a closed position in fig. 1, in an extended position (TV position) in fig. 2, and in a reclined position in fig. 3. For illustrative purposes, fig. 1-3 only show a portion of the elements that may be included in the seating unit 10, and various other possible components have been omitted. Generally, the seating unit 10 has a seat sub-structure 12, a backrest sub-structure 14, a linkage 100, a first bench sub-structure 16, and a second bench sub-structure 18 (fig. 2). The under-seat structure 12 and the under-backrest structure 14 are movable relative to the base of the seating unit 10 and relative to each other, as shown by the positions shown in fig. 1-3. In an embodiment, the linkage 100 facilitates movement of the seating unit 10 to the position shown in fig. 1-3. That is, the linkage 100 is arranged to pivotally actuate and control movement of the seat lower structure 12, the backrest lower structure 14, and the stools 16 and 18 between the positions shown in fig. 1-3, as described more fully below.

Fig. 1 shows the seating unit 10 adjusted to a closed position, which is a generally non-reclined seating position with the understructure 12 in a generally horizontal position and the back understructure 14 generally upright and in a generally vertically offset relationship with the seat understructure 12. In particular, the understructure 12 may be arranged in a slightly inclined orientation relative to the base of the seating unit 10. In one embodiment of the invention, this tilt direction may be maintained throughout adjustment of the seating unit 10 between the non-reclined position, the extended position, and the reclined position. When in the closed position, the bench understructures 16 and 18 are positioned substantially below the seat understructure 12 and other seating structures of the seat unit 10.

Turning to fig. 2, an extended position (TV position) is shown. When the seating unit 10 is adjusted to the extended position, the first and second stool structures 16, 18 extend from under the seat of the seating unit 10. Furthermore, the backrest remains substantially perpendicular to the seat. As will be described in more detail in other portions of this specification, as the seat plate of the seat unit moves forward (i.e., to the left with respect to the view shown in fig. 1-3), the backrest of the seat unit does not abut an adjacent wall (i.e., is positioned to the right of the view shown in fig. 1-3) when the seat unit 10 is moved to the extended position. The under-seat structure 12 is maintained in an inclined orientation relative to the seat unit base. Thus, the configuration of the seating unit 10 in the extended position shown in fig. 2 provides a reclined TV position for the user while providing space-saving utility.

Fig. 3 shows a reclined position in which the seating unit 10 is fully reclined. The backrest understructure 14 is rotated rearward and offset by a rearward tilt angle by the linkage 100. The rear tilt angle is typically in obtuse relationship with the understructure 12. However, the back tilt angle of the backrest, when controlled by the linkage 100, is offset by the forward and upward translation of the seat 12. This is in contrast to some other recliners having a 3-position mechanism that move their backrest rearward during adjustment, requiring the recliner to be positioned a substantial distance from an adjacent rear wall or other proximate stationary object. Thus, forward and upward translation of the under-seat structure 12 in embodiments of the present invention allows for zero wall clearance. Generally, "zero wall clearance" is used herein to indicate space-saving utility that allows positioning of the seating unit 10 immediately adjacent rear walls and other stationary objects. In an embodiment of the present invention, the stools 16 and 18 may be moved further forward and upward as they move from the extended position to the reclined position.

As mentioned above, fig. 1-3 only show some elements of the seating unit 10; however, in other embodiments of the present invention, the seating unit 10 includes various other components, such as armrests, legs, and the like. For example, in the case of a chair of the Pivoting On Arm (POA) style, the arm will interconnect with the seat and linkage 100 such that the legs of the seating unit do not directly support the arm. Instead, the legs support the lower frame of the seating unit 10 so that the seat can move along with the armrests. In the POA configuration, the back may include wings that extend over the armrests and pivot about the rear of the armrests upon recline of the back. In an alternative configuration known as a nested frame style, the armrests are stationary relative to the seat 12 that is adjustable via a linkage. In this embodiment, the seat 12 may move during adjustment of the seat unit 10, but the armrests remain relatively stationary.

Fig. 4-7 illustrate a configuration of a linkage 100 for a manually adjustable zero wall gap seating unit 10 (hereinafter "seating unit") designed to provide an additional layout when adjusted to a reclined position. As described above, the linkage 100 is arranged to pivotally actuate and control movement of the seat, backrest, and bench of the seating unit between the positions shown in fig. 4-7. That is, the linkage 100 may be adjusted to a reclined position (fig. 4 and 5), an extended (TV) position (fig. 6), and a closed position (fig. 7). In the reclined position, the back rotates rearward and is biased at a rearward tilt angle that is in obtuse relationship with the seat. When the seating unit 10 is manually adjusted to the extended position, the bench still extends forward, while the back is angularly biased substantially perpendicular to the seat. The closed position is configured to be a seating position in which the seat is in a substantially horizontal position, while the backrest is still substantially upright. During adjustment between the closed position, the extended position, and the reclined position, the linkage 100 includes a seat adjustment assembly 500 in which the rear bell crank 530 is adapted to translate the seat mounting plate 400 on the base plate 410 in a constant tilt direction relative to the base plate 410.

Furthermore, the linkage 100 comprises a plurality of other linkages arranged to actuate and control movement of the seat unit during movement between the closed position, the extended position and the reclined position. These linkages can be pivotally interconnected. It is to be understood and appreciated that the pivotal coupling between these linkages (shown as pivot points in the figures) can take a variety of configurations, such as pivot pins, bearings, conventional mounting hardware, rivets, bolt and nut combinations, or other suitable fasteners known in the furniture manufacturing industry. In addition, the shape of the links and brackets may vary, as may the location of certain pivot points. It will be understood that when a linkage is referred to as being pivotally "coupled" to another element (e.g., linkage, backrest, frame, and the like), being "interconnected with," "attached to" the other element, etc., it is contemplated that the linkage and element are in direct contact with each other, or that other elements (e.g., intervening elements) may also be present.

Typically, in operation, the linkage 100 directs the rotation of the backrest, seat, and bench. In an exemplary configuration, these movements are controlled by a pair of substantially mirror-image linkages (one of which is shown and indicated herein with reference numeral 100), including a configuration of pivotably interconnected linkages. The linkage is disposed in opposing facing relation to a longitudinally extending plane dividing the seating unit in half between a pair of opposing arms. Accordingly, the following discussion focuses on only one of the linkages 100, and the disclosure applies equally to other complementary linkage assemblies.

With continued reference to fig. 4, a partial perspective view of the linkage 100 in a reclined position is illustrated in accordance with one embodiment of the present invention. In an embodiment, the linkage mechanism 100 includes a footrest assembly 200, a seat mounting plate 400, a base plate 410, and a seat adjustment assembly 500. The footrest assembly 200 includes a plurality of links that are configured to extend and fold the footrest, respectively, when the seat unit is adjusted from the extended position to the closed position. The seat mounting plate 400 is configured to be fixedly mounted to a seat sub-structure (fig. 1-3) and cooperatively opposed seat mounting plates define a seat support surface (not shown). The seat adjustment assembly 500 includes a back mounting link 510, a rear bell crank 530, a sequence adjustment link 550 (see fig. 11-14), and a plurality of other links. In general, the seat adjustment assembly 500 is adapted to recline and tilt the back substructure 14 (fig. 1-3) coupled to the back mounting link 510, as well as to laterally translate the seat substructure 12 coupled to the seat mounting plate 400.

Referring to fig. 4-7, the components of the linkage 100 will now be discussed in detail. As briefly mentioned above, the linkage mechanism 100 includes the footrest assembly 200, the seat mounting plate 400, the base plate 410, and the seat adjustment assembly 500. The footrest assembly 200 includes a front stool link 110, a rear stool link 120, an inner stool link 130, a middle stool bracket 140, an outer stool link 150, and a stool bracket 170. The front stool link 110 is rotatably coupled to the seat mounting plate 400 at pivot 115. The front stool link 110 is pivotally coupled to the inner stool link 130 at pivot 113 and to the outer stool link 150 at pivot 117. In addition, the front stool link 110 includes a front stop element 422 for adjustment from a closed position to an extended position when the inner stool link 130 is in contact therewith.

The front stool link 110 is also pivotally coupled to the footrest lock link 370 at pivot 111. Foot pedal locking link 370 is indirectly coupled with actuator lever 350 via actuator bracket 360 (fig. 5 and 11), wherein actuator lever 350 is manually or automatically rotated to control the extension or folding of foot pedal assembly 200. The pivotable coupling 111 between the footrest lock link 370 and the front stool link 110 opposite the rear stool link 120 provides an over-center locking configuration that reduces slackening or sagging of the footrest assembly 200 when in the closed position (fig. 7). In other words, the pivotable coupler 111 of the foot pedal locking link 370 is located forward of the comparable pivot connection location in the other mechanisms. This forward position of pivot 111 eliminates potential slack in the links rearward of pedal assembly 200.

The rear stool link 120 is rotatably coupled to the seat mounting plate 400 at pivot 121 and rotatably coupled to the inner stool link 130 at pivot 133. In addition, the rear stool link 120 is pivotally coupled to the footrest drive link 590 of the seat adjustment assembly 500 at pivot 125. During adjustment between the closed position and the extended position, forward force transmitted to the pivot 125 through the foot pedal drive link 590 and to the pivot 111 through the foot pedal lock link 370 causes the foot pedal assembly 200 to be urged out to the extended position.

The inner stool link 130 is pivotally coupled at one end to the rear stool link 120 at pivot 133 and to the front stool link 110 at pivot 113. At the opposite end, the inner stool link 130 is pivotally coupled to the footrest bracket 170 at pivot 172. Intermediate stool support 140 is pivotally coupled to the end of the inner stool link 130 at pivot 135. The intermediate stool bracket 140 is also pivotally coupled to the outer stool link 150 at pivot 141. The outer stool link 150 is also pivotally coupled to the front stool link 110 at pivot 117 and to the stool support 170 at pivot 175.

The seat adjustment assembly 500 includes an actuator bracket 360 (fig. 5 and 11), a footrest lock link 370, a front lift link 440, a front pivot link 450, a bracket link 460, a front bell crank 485, a back mounting link 510, a rear control link 520, a rear bell crank 530, a lap link 535, a rear pivot link 540, a sequence adjustment plate 550 having a guide slot 555 formed therein, a sequence adjustment element 560 that travels within the guide slot 555, a front sequence adjustment link 570, and a footrest drive link 590. The actuator lever 350 is rotatably coupled to the seat-mounting plate 400. Typically, the actuator lever 350 spans the undercarriage of the seating unit as shown in fig. 8, and is also rotatably coupled with a complementary seat-mounting plate of the mirror-image linkage.

Typically, the actuator lever 350 is adapted to receive actuation of the adjustment by a user between a closed position and an extended position. In particular embodiments, the actuator lever 350 may be controlled manually (e.g., a user may apply a manual rearward force on the handle or may apply a force on a release lever of the cable actuator) or automatically (e.g., a user may trigger a control signal to the linear actuator 300), as discussed more fully below with reference to fig. 8A-8D and 18A-18D. The actuator rod 350 is fixedly attached at its upper end to an actuator bracket 360 (fig. 11). The lower end of the actuator bracket 360 is pivotally coupled to a rear portion 372 of the foot pedal locking link 370 at pivot 365, as best shown in fig. 11.

Referring to the manually operated embodiment of the invention, the interconnection of the actuator bracket 360 and the foot pedal locking link 370 converts the torque (rotational force) applied to the actuator lever 350 by the user into forward and upward thrust (directional force) acting on the pivot 111 of the foot pedal assembly 200. That is, referring to fig. 11, a counterclockwise moment applied to the actuator lever 350 translates into an upward and forward translation of the foot pedal lock link 370 that initiates extension of the foot pedal assembly 200 from the closed position (fig. 1 and 7) to the extended position (fig. 2 and 6).

As described above, the pivot 111 couples the front 371 of the footrest lock link 370 to the front stool link 110 of the footrest assembly 200. Unlike conventional 4-bar extension mechanisms, upward and forward pushing is directed to the front stool link 110 opposite the rear stool link. Thus, the configuration of fig. 4-7 enables the pedal assembly 200 to be significantly extended, yet provides the pedal assembly 200 with a compact folded size when in the closed position. The compact folded size enables the footrest assembly 200 to be positioned below the seat support surface and above a lower surface of at least one cross member (described below) when in the closed position.

In operation, upon application of a forward and upward push (via the footrest lock link 370) on the pivot 111, the front stool link 110 rotates forward about the pivot 115, causing the footrest assembly 200 to extend. The forward rotation of the front stool link 110 affects the forward rotation of the rear stool link 120 about the pivot 121. Typically, as a result of the configuration of the pivots 133 and 113, the front and rear stool links 110 and 120 rotate in a substantially parallel spaced relationship. Rotation of the front stool link 110 and the rear stool link 120 produces upward movement of the outer stool link 150 and the inner stool link 130, respectively. During their upward movement, the outer stool link 150 and the inner stool link 130 cooperate to raise and rotate the intermediate stool bracket 140 and the footrest bracket 170, respectively, to a generally horizontal orientation. Accordingly, the first ottoman 16 (see fig. 1-3) supported by the footrest bracket 170 and the second ottoman 18 supported by the intermediate bench bracket 140 are movable from a position below the seat-supporting surface to an extended, horizontally oriented position. Retraction of the foot pedal assembly 200 is triggered by a clockwise moment at the actuator lever 350 (in the position shown in fig. 11) that pulls the foot pedal lock link 370 upon translation downward and rearward. Typically, this downward and rearward translation causes movement of the foot pedal mechanism 200 in opposition to the steps described above with reference to the extend operation.

Referring to fig. 5-7, other components of the seat mount assembly 500 will now be discussed. Beginning at a rearward point of the seat mount assembly 500, the back mount link 510 is rotatably coupled to a rear portion 902 (see fig. 9) of the seat mount plate 400 at pivot 401. Further, the back mounting link 510 is pivotally coupled to an upper portion 521 of the rear control link 520 at pivot 511. Rear control link 520 is pivotally coupled to back mounting link 510 at an upper portion 521 at pivot 511 and pivotally coupled to rear bell crank 530 at a lower portion 522 at pivot 525.

Rear bell crank 530 includes an upper portion 539, a lower portion 537, and a front portion 538. The rear bell crank 530 is rotatably coupled at a lower portion 537 thereof to a middle portion 409 (see fig. 9) of the seat-mounting plate 400 at a pivot 536. In addition, the rear bell crank 530 is pivotally coupled to the lower portion 522 of the rear control link 520 at pivot 525 at lower portion 537. Further, rear bell crank 530 is pivotally coupled to upper portion 543 of rear pivot link 540 at pivot 541 at upper portion 539. A lower portion 544 of the rear pivot link 540 is rotatably coupled to the rear end 416 of the base plate 410 at a pivot 542. Generally, this interconnection of the rear control link 520, the rear pivot link 540, and the rear bell crank 530 is adapted to translate the seat mounting plate 400 on the base plate 410 during adjustment between the closed position, the extended position, and the reclined position, while maintaining the angular orientation relationship therebetween. In one exemplary embodiment, the seat-mounting plate 400 may be biased at a substantially uniform tilt angle with the base plate 410 throughout adjustment between the closed position, the extended position, and the reclined position. Further, the interconnection of the rear control link 520, the rear pivot link 540, and the rear bell crank 530 is adapted to recline the back 14 (see fig. 1-3) while the seat mount 400 translates in a forward and upward direction over the base plate 410. Accordingly, zero wall gap capability is achieved.

The rear bell crank 530 includes a rear stop member 420 (fig. 6 and 7) to prevent additional tilting of the back mounting link 510 when the rear pivot link 540 is in contact therewith, as shown in fig. 7. Thus, the position of the rear stop element 420 on the rear bell crank 530 at least partially determines the degree of allowable rearward bias of the backrest and defines the configuration of the linkage 100 when adjusted to the closed position. Rear bell crank 530 is also pivotally coupled at pivot 533 to rear 532 of overlap link 535 at front 538. The overlap link 535 is pivotally coupled to the intermediate portion 447 of the front lift link 440 at pivot 436 at front 531.

In another embodiment, the stop element 513 extends from the seat mounting plate 400. When in either the upright position (e.g., fig. 7) or the TV position (e.g., fig. 6), the stop element 513 engages a portion, such as a side or edge, of the back mounting link 510 to block forward tilting of the back mounting link 510. For example, the back mounting link 510 may include an extension or finger 515 extending from the back mounting link 510 and contacting the stop element 513. Further, when moved to the fully reclined position (e.g., fig. 5), the stop member 513 engages another portion of the back mounting link 510 to block further recline of the back mounting link. For example, the back mounting link 510 may include a catch plate 517 generally opposite the finger 515 and engaging the stop element 513. In one embodiment, the stop element 513 (e.g., a pivot) is engaged with at least two different portions of the backrest mounting link 510, and each of the at least two different portions includes a respective edge. In a further embodiment, the respective edges extend along planes intersecting as indicated by dashed lines in the enlarged portion of fig. 5, for example. For example, the planes may intersect in a near vertical orientation.

Positioning the stop element 513 to engage the back mounting link 510 in the fully upright and fully reclined positions has a number of purposes. For example, based on the gaps in the plurality of crimp joints between the rear pivot link 540 and the backrest mounting link 510, the backrest mounting link can rotate forward even when the linkage is in the upright position, without the presence of the stop element 513. The stop 513 is positioned relative to the back mounting link 510 to form a preload that further limits forward movement of the back mounting link 510. This also provides for more consistent alignment of the back rest in multi-seat furniture such as three-person sofas and sectional furniture. The location of the stop element 513 engaged with the back mounting link 510 also helps prevent bending of the back mounting link 510 and the rear pivot link 540 in the fully reclined position. That is, in the absence of the stop element 513, there is a risk of bending when a sufficiently large force is applied back on the chair back (e.g., by a person in the chair). To address this risk, the back-mount link 510 may be made of heavier steel. However, by locating the stop element 513 on the seat plate 2400 and at the back mounting link 510, the back mounting link 510 may be made of thinner steel to reduce costs.

In fig. 5, the fingers 515 and catch plate 517 are merely exemplary, and the back mount link 510 may include various other configurations designed to contact the stop element 513 at different locations to control the tilt and recline of the back mount link 510. For example, instead of forming elements protruding from the outer periphery of the backrest mounting link 510, a cutout may be formed in the outer periphery to form a first engagement edge similar to the finger 515 and a second engagement edge similar to the catch plate 517. That is, the backrest mounting link 510 includes an outer periphery and a body 509, and a cutout may extend inwardly from the outer periphery into the body 509.

In one embodiment, the portion of the back mounting link 510 that engages the stop element 513 is configured to limit the amount of recline relative to the vertical position to about 49 degrees. For example, the distance between the finger 515 (i.e., the first engagement edge) and the catch plate 517 (i.e., the second engagement edge) forms a gap that defines the travel path of the stop element 513 as the back-mounting link 510 pivots. The travel path may be configured to control the amount of recline allowed. In one embodiment of the present invention, when a stop having a diameter of about 0.450 "is used, the travel distance of the stop 513 is in the range between about 0.80" to about 1.20 ". Thus, the configuration may also be a ratio of this distance to diameter. The stop element 513 may be used alone or in combination with other stops described herein to limit the range of motion of the linkage.

In an embodiment, front lift link 440 includes a rear portion 446, a front portion 445, and a middle portion 447. As described above, the middle portion 447 of the front lift link 440 is pivotally coupled to the front portion 531 of the overlap link 535 at pivot 436. The front lift link 440 is rotatably coupled to the front 901 of the seat mounting plate at a rear 446 at a pivot 441 (see fig. 9). In addition, front lift link 440 is pivotally coupled to an upper portion 456 of front pivot link 450 at pivot 452 at front 445. Front pivot link 450 is rotatably coupled to front end 415 of base plate 410 at a lower portion 457 at a pivot 453 (see fig. 9).

In the case of the present invention, the front pivot link 450 includes a middle portion 458 pivotally coupled to the lower portion 463 of the bracket link 460 at pivot 451. The bracket link 460 is pivotally coupled to a front bell crank 485 at pivot 461 at upper 464. Typically, front bell crank 485 includes an upper portion 481, a lower portion 483, and a front portion 482, as shown in FIG. 7. An upper portion 481 of front bell crank 485 is pivotally coupled to bracket link 460 at pivot 461, as described immediately above. A pivot 487 at the middle portion 482 of the front bell crank 485 rotatably couples the front bell crank 485 to the middle portion 409 of the seat mounting plate 400 (see fig. 9). The lower portion 483 of the front bell crank 485 is pivotally coupled to the rear end 591 of the pedal drive link 590 at pivot 486. The front end 592 of the footrest drive link 590 is pivotally coupled to the rear stool link 120 of the footrest assembly 200 at pivot 125.

With continued reference to fig. 4-7, the operation of the seat adjustment assembly 500 according to one embodiment of the present invention will be described. First, an operator initiated rearward seating force may be received at the backrest. As described above, the back mounting link 510 cooperates with a complementary back mounting link of the mirror image linkage to support the back of the seating unit. In one embodiment of the manually adjustable seating unit, the rearward force of the user oriented at the backrest should overcome the balance threshold to bias the backrest mounting link 510 rearward, thereby effecting movement from the extended position (fig. 6) to the reclined position (fig. 5). The balance threshold may be substantially defined by the ratio of rearward user force on the backrest to downward user weight on the seat. In operation, the downward force of the user's weight pushes down on the seat mounting plate 400, while the rearward force of the user's action on the backrest pushes up and forward on the seat mounting plate 400 through the interconnection of the backrest mounting link 510, the rear control link 520, the rear bell crank 530, the rear pivot link 540, and the base plate 410. (it should be noted that the equilibrium threshold may be applied in a manual adjustment style seating unit, while an automated adjustment style seating unit relies on a motor or other linear actuator to adjust the linkage 100 between the extended and reclined positions.) thus, the rearward force overcomes the downward force to cause adjustment of the seating unit.

Once the user overcomes the equilibrium threshold by counteracting his/her weight in the seat or tilting back on the backrest by applying sufficient rearward force, rearward movement (clockwise rotation from the perspective of FIG. 5) of the backrest mounting link 510 about the pivot 401 can be achieved and adjustment from the extended position to the reclined position begins. The rearward rotation generates a torque about pivot 511. The torque is converted to a transversely oriented force by the rear control link 520. Accordingly, the rear control link 520 transmits laterally oriented forces between the back mounting link 510 and the rear bell crank 530. Typically, the rear control link 520 creates a clockwise torque on the rear bell crank 530 about the pivot 536. Rear bell crank 530 converts the clockwise torque into a downward force directed through rear pivot link 540, and rear pivot link 540 rotates about rear end 416 of base plate 410 at pivot 542.

This rotation enables the seat-mounting plate 400 to translate forward and upward relative to the base plate 410 during adjustment from the extended position to the reclined position. In an embodiment, the links 510, 520, and 540 and the rear bell crank 530 are designed to translate the seat mounting plate 400 such that the seat remains biased at a substantially uniform tilt angle with the base plate 410 when adjusted from the TV position to the fully reclined position. In addition, the links 510, 520, and 540 and the rear bell crank 530 are designed to translate the seat-mounting plate 400 forward at a greater speed than the rearward rotation of the back-mounting link 510, thereby achieving zero wall clearance.

Forward translation of the seat-mounting plate 400 is also affected by the linkages 535, 440, and 450. In a particular embodiment, a clockwise torque on rear bell crank 530 about pivot 536 (applied by the user) generates a laterally oriented force on overlap link 535 for pulling forward lifting link 440 rearward. This rearward pulling results in a counterclockwise rotation of the front lift link 440 about pivot 441, the pivot 441 rotatably coupling the front lift link 440 to the seat mounting plate 400. This counter-clockwise rotation is eventually prevented by the inner intermediate stop member 421. When the front lifting link 440 is in contact with the inner intermediate stop member 421, a full adjustment to the reclined position is achieved. The counterclockwise rotation of the front lift link 440 also creates a laterally directed force on the front end 415 of the base plate 410 via the front pivot link 450. This laterally directed force causes the front pivot link 450 to swing forward about pivot 453, thereby effecting forward translation of the seat mounting plate 400 relative to the base plate 410.

Rearward seating forces on the release backrest below the equilibrium threshold (e.g., by the user leaning forward) allows the back mounting link 510 to be biased forward. In particular, the downward seating force allows the rear pivot link 540 to push upward on the rear bell crank 530, thereby creating its counterclockwise rotation. The counterclockwise rotation transfers the laterally directed force through the laterally directed force for rotating the back mounting link 510 in a counterclockwise manner. That is, the laterally directed force exerted by the rear control link 520 enables the back mounting link 510 to move forward to a substantially upright orientation. In one example, a stop element (not shown) extending from the rear bell crank 530 prevents continued rotation thereof upon contact with the seat-mounting plate 400; thereby inhibiting further forward tilting of the backrest when in the closed or extended position.

As described above, according to one embodiment of the invention, the size and geometry of the various links and pivots are variable, which allows the linkage 100 to be configured to achieve the desired functionality. The various links and pivots may be configured to control the amount of forward and upward translation of the seat-mounting plate 400 relative to the base plate 410. 17A-17C illustrate one example of an embodiment in which the linkages of the linkage 100 have different dimensions. Examples of variable dimensions include: the distance between the pivot 542 and the pivot 453 of the base plate 410; the distance between the pivots 541 and 542 of the rear pivot link 540; the distance between pivots 452 and 453 of front pivot link 450; the distance between pivot 533 and 436 of overlap link 535; the distance between the pivots 451 and 461 of the front control link 460; and the shape of the front bell crank 485.

In one embodiment of the invention, the distance between the pivots 541 and 542 of the rear 540 and between the pivots 452 and 453 of the front pivot link 450 affects the forward translation of the seat-mounting plate 400 relative to the base plate. For example, increasing the distance between pivots 541 and 542 and increasing the distance between pivots 452 and 453 facilitates increased forward translation of seat-mounting plate 400, which improves the zero wall feature (e.g., wall clearance) of the linkage mechanism. Reducing the distance between these pivots helps to improve the seat-to-linkage gap.

In one embodiment of the invention, the distance between the pivots 541 and 542 is in the range of from about 7 inches to about 8.6 inches, preferably from about 7.3 inches to about 8.6 inches. For example, in one embodiment, to create the desired amount of forward translation of the seat-mounting plate 400, the distance between the pivots 541 and 542 is about 8.6 inches, and more particularly about 8.573 inches (e.g., fig. 17A-17C). In another embodiment, to form the desired amount of seat gap, the distance between pivots 541 and 542 is about 7.3 inches, and more particularly about 7.328 inches (e.g., fig. 4-7). In yet another embodiment of the present invention, the distance between pivots 452 and 453 is in the range of from about 8.5 inches to about 10 inches, preferably from about 8.7 inches to about 9.8 inches. For example, in one embodiment, to create the desired amount of forward translation of the seat-mounting plate 400, the distance between the pivots 541 and 542 is about 9.8 inches, and more particularly about 9.804 inches (e.g., fig. 17A-17C). In another embodiment, to form the desired amount of seat gap, the distance between pivots 541 and 542 is about 8.7 inches, and more particularly about 8.714 inches (e.g., fig. 4-7).

The distance between the pivots may be defined as a ratio of each other. For example, if some or all of the linkage 100 dimensions are scaled up or down by a factor, the ratio may be used to determine the appropriate distance between the pivots. Thus, in one embodiment of the invention, the distance ratio between pivots 541 and 542 and pivots 452 and 453 is about 8.6:9.8, which creates the desired amount of forward translation of the seat-mounting plate (e.g., fig. 17A-17C). In another embodiment of the present invention, the distance ratio between pivots 541 and 542 and pivots 452 and 453 is about 7.3:8.7, which creates the desired amount of seat gap (e.g., fig. 4-7).

In another embodiment of the present invention, the relative positions of front pivot link 450, front lift link 440, and front bell crank 485 are displaced forward relative to the other elements of linkage 100. For example, the pintle 453 of the front pintle link 450 may be disposed further forward on the base plate 410 such that the distance between the pintle 542 and the pintle 453 increases and the pintle 453 is further displaced toward the front of the base plate 410. Further, the pivot 411, at which the front lift link 440 is attached to the seat mounting plate 400, and the pivot 487, at which the front bell crank 485 is attached to the seat mounting plate 400, are displaced forward.

When the linkage is configured, displacing forward pivot link 450, forward lift link 440, and forward bell crank 485 in combination with other elements of linkage 100 may facilitate higher upward translation of seat plate 400 relative to base 410. For example, the distance between the pivots 451 and 461 of the bracket link 460 affects the upward translation of the seat plate 400 relative to the base plate 410. That is, increasing the distance between pivots 451 and 461 facilitates increased upward translation, which improves the layout features of the linkage. The layout features improve because the seat and chair move at a faster rate to balance the back recline.

In one embodiment of the invention, the distance between pivots 451 and 461 is in the range of from about 8 inches to about 8.6 inches. For example, in one embodiment, the distance between the pivots 451 and 461 is about 8.1 inches, and more particularly about 8.077 inches (e.g., fig. 4-7). In another embodiment, to increase the upward translation of the seat-mounting plate 400, the distance between the pivots 451 and 461 is about 8.5 inches and more specifically about 8.535 inches (e.g., fig. 17A-17C). Thus, one embodiment of the present invention shown in FIGS. 17A-17C includes displacing forward (relative to the embodiment shown in FIGS. 4-7) the front pivot link 450, the front lift link 440, and the front bell crank 485 forward (relative to the seat mounting plate 400) and configuring the distance between the pivots 451 and 461 to be about 8.5 inches.

The forward displacement of the front pivot link 450, front lift link 440, and front bell crank 485 may be defined in various ways. For example, the pivot 487 may attach the front bell crank 485 to the seat mounting plate 400 in various locations. In the first configuration, a distance of about 4 inches may extend between the pivots 487 and 536 (e.g., fig. 4-7). In the second configuration (e.g., fig. 17A-17C) where the front bell crank 485 is displaced forward, there may be a distance of about 4.5 inches between the pivot 536 and the pivot 487 of the front bell crank 485 such that the pivot 487 is displaced horizontally forward by about 0.9 inches compared to the first configuration.

In the embodiment shown in fig. 4-7, front bell crank 485 includes a stick-like configuration that allows front bell crank 485 to rotate about starter rod 350. That is, the bending of the front bell crank 485 allows the front bell crank 485 to rotate without colliding with the transmission 350 when moving from the closed position (e.g., fig. 7) to the extended position (e.g., fig. 6). However, when the front bell crank 485 is displaced forward to avoid interference with the actuator rod 350, the curvature of the front bell crank 485 may be configured differently. For example, a groove may be positioned in the outer periphery of the front bell crank 485 or in the middle of the front bell crank 485 (e.g., fig. 17B and 17C) that provides a travel path for the actuator rod 350 as the front bell crank rotates about the actuator rod 350.

Referring now to fig. 8A-8D and 18A-18D, an automated version of the linkage 100 is shown and will now be described by way of the following embodiments. In one embodiment, the automated format includes a double linkage configuration as shown in fig. 8A-8D. In an alternative embodiment, the automated version includes a single drive link configuration as shown in FIGS. 18A-18D.

Referring now to fig. 8A-8D, the automated version may include a linear actuator 300 including an angle bracket 315 secured to an actuator lever 350 (described above), a motor mechanism 320, and a track 330 interconnecting the motor mechanism 320 and the motor actuator module 340. Further, the linear actuator may include a right motor link 380 and a left motor link 390 maintained in a substantially parallel spaced apart relationship with each other. In addition, a support assembly 600 may be provided that serves as a foundation for resting on a surface below the seating unit.

In particular, the support assembly 600 may be used to house the linear actuator 300. The support assembly 600 shown in fig. 8 may include a front cross member 610 and a rear cross member 620 maintained in a substantially parallel spaced apart relationship with the front cross member 610. The cross members 610 and 620 serve to support the linear actuator 300 and the substrate 410 above the underlying surface. The support bushings 411 and 412 of fig. 5 and 15 are provided to raise the linear actuator 300 and the substrate 410 to a certain level above the underlying surface.

In an embodiment, cross members 610 and 620 function as a cross beam spanning between base plate 410 of linkage 100 and a complementary base plate incorporated within a mirror-image linkage disposed in a substantially parallel spaced-apart relationship with linkage 100. In addition, the cross members 610 and 620 may be formed of a metal stock. Similarly, the seat-mounting plate 400, the base plate 410, and the plurality of links comprising the linkage 100 are typically formed from a metal stock such as stamped steel. However, it is to be understood and appreciated that any suitable rigid or sturdy material known in the furniture industry may be used in place of the above materials.

In the embodiment of the linear actuator 300, the motor mechanism 320 is protected by a housing coupled or secured to the front cross member 610. The motor mechanism 320 is operably coupled to the front end of the track 330. The rear end of the rail 330 is coupled or fixedly attached to the rear cross member 620. The track 330 includes a first travel section 331 and a second travel section 332. The motor starter module 340 is configured to translate or slidably engage longitudinally along the track 330 under the automated control of the motor mechanism 320. The right and left motor links 380 and 390 are pivotally coupled to the motor starter module 340 and are pivotally coupled to corner brackets 383 and 393 (respectively) extending from the corner bracket 315 by means of pivots 382 and 392.

As described above, the linkage 100 is coupled to a linear actuator 300 that provides powered adjustment of the linkage 100 between the reclined position, the extended position, and the closed position. In one exemplary embodiment, the motor starter module 340 moves toward or away from the motor mechanism 320 during automated adjustment of the linkage 100. In a particular embodiment, the motor mechanism 320 controls movement of the motor starter module 340 along the travel sections 331 and 332 of the track 330.

In operation, a control signal from a user of the seating unit or elsewhere may trigger the motor mechanism 320 to cause longitudinal translation of the motor starter module 340, which in turn causes movement of the linkage 100. As discussed more fully below, the sliding motion is adjusted in sequence into a first phase and a second phase. During the first phase, the motor mechanism 320 moves the motor starter module 340 forward relative to the motor mechanism 320 while the motor mechanism 320 remains generally fixed in position, thereby adjusting the seat adjustment assembly 500 from the closed position (fig. 7 and 8B) to the extended position (fig. 6 and 8C).

The adjustment in the first stage includes causing the motor starter module 340 to traverse or slide longitudinally along the first travel section 331 of the track 330. Such traversing of the motor starter module 340 within the first travel section 331 generates forward and upward thrust forces at the motor links 380 and 390 pushing on the angle bracket 315, thereby rotatably adjusting the starter lever 350. That is, the traversing of the motor starter module 340 within the first travel section 331 toward the motor mechanism 320 causes the angle bracket 393 to rotate clockwise (based on the view provided by fig. 8B) on the pivot 392, thereby rotating the angle bracket 315 and the starter bar 350 clockwise. Fig. 8C provides an exemplary illustration of the angle bracket 393, angle bracket 315, and actuator lever 350 after a clockwise rotation from fig. 8B. As described above, the rotatable adjustment of the actuator lever 350 controls the adjustment of the seating unit in the closed position and the extended position (i.e., the extension foot pedal assembly 200).

Once the stroke of the first phase is substantially complete, the second phase begins. During the second phase, the motor starter module 340 is again moved forward relative to the motor mechanism 320 while the motor mechanism 320 remains substantially fixed in position. In an embodiment, the adjustment in the second stage includes causing the motor starter module 340 to traverse longitudinally along the second travel section 332 of the track 330. With the linkage fully extended and the actuator rod 350 prevented from further rotation, such traversing of the motor actuator module 340 within the second travel section 332 creates forward and upward thrust forces at the motor links 380 and 390 pushing on the angle bracket 315, thereby translating the actuator rod 350 forward and upward relative to the base plate 410. This translation of the actuator lever 350 controls the adjustment of the seating unit between the extended and reclined positions (i.e., the adjustment of the seat adjustment assembly 500 is initiated without the aid of a rearward force on the backrest by the user). For example, forward and upward translation of the actuator rod 350 causes the seat plate 400 to also move forward and upward, which in turn causes the back mounting link 510 to rotate clockwise on the pivot 401.

In one example, the combination of the motor mechanism 320, the track 330, and the motor starter module 340 is implemented as an "electric" linear actuator 300. In this example, the linear actuator 300 is controlled by a manually operated controller that provides instructions thereto. These instructions may be provided upon detection of actuation of a user initiated manually operated control. Further, the instructions may cause the linear actuator 300 to perform a complete first stage and/or second stage movement. Alternatively, the instructions may cause the linear actuator 300 to partially complete the first stage and/or the second stage movement. Thus, the linear actuator 300 may be able to move to and remain in various positions within the first stage or second stage of travel in an independent manner.

While a particular configuration of the combination of motor mechanism 320, track 330, and motor starter module 340 has been described, it is to be understood and appreciated that other types of suitable devices that provide sequential adjustment may be used, and embodiments of the present invention are not limited to linear actuators 300 as described herein. For example, the combination of motor mechanism 320, track 330, and motor starter module 340 may be implemented as a telescoping device that extends and retracts in a sequential manner.

In another embodiment of the present invention, the automated version includes a single drive link configuration as shown in fig. 18A-18D. The embodiment shown in fig. 18A-18D is similar to that of fig. 8A-8D in that the motor 1818 is attached to the rail 1820 and the motor is attached to the front cross member 610, with one end of the rail 1820 being attached to the rear cross member 620. In addition, the motor starter module 1812 is slidably attached to the track 1820 such that the motor starter module 1812 may traverse along the track 1820 with the motor 1818 (or some other linear actuator). Generally, as the motor activator module 1812 traverses the track 1820, the drive link 1810 causes the seating unit to move between the folded position, the extended position, and the reclined position.

The structure of the embodiment shown in fig. 18A-18D differs from fig. 8A-8D in various respects. For example, the two drive links 380 and 390 (e.g., fig. 8A) are replaced by a single drive link 1810 (e.g., fig. 18A). In addition, in fig. 18A-18D, the motor starter module 1812 and the corner brackets 1814 and 1816 are differently configured.

In one embodiment of the invention, the motor starter module 1812 includes a carrier body 1822 that slidably couples the motor starter module 1812 to the rail 1820. For example, the carrier body 1822 may include a hole (not shown) through which the rail 1820 protrudes when the motor starter module 1812 is slidably coupled to the rail 1820. In addition, the motor starter module 1812 includes one rearwardly extending mounting tabs 1824 and 1825, each of which includes a corresponding aperture.

The mounting tabs 1824 and 1826 include a gap therebetween, and one end of the drive link 1810 fits within the gap. The apertures of the mounting tabs 1824 and 1826 receive a single fastener that also protrudes through an aperture in the end of the drive link 1810 inserted in the gap to pivotally attach the drive link 1810 to the motor starter module 1812 at pivot 1828. Thus, the drive link 1810 is pivotally attached at one end to the motor starter module 1812 by a pivot 1828. The opposite ends of drive link 1810 are engaged between corner brackets 1814 and 1816 and pivotally attached to corner brackets 1814 and 1816 at pivot 1830 by a single fastener. Furthermore, two corner brackets 1814 and 1816 are attached to the corner bracket 315. For example, each corner bracket 1814 and 1816 may be attached to the corner bracket using a respective single fastener.

The operation of the linear actuator (e.g., motor 1818) and the single drive link 1810 will now be described with reference to fig. 18D, which shows a state diagram of the drive members at various stages. For example, fig. 18D shows the drive members of the mechanism as it is adjusted between a closed position 1840, an extended position 1842, and a reclined position 1844.

In the closed position 1840, the electric machine 1818 biases the motor starter module 1812 rearward, thereby maintaining the mechanism in a closed position (e.g., fig. 1 and 7), and the drive link 1810 is in a generally horizontal orientation as viewed from the side of fig. 18D. From the closed position 1840, actuation of the motor 1818 slides the motor starter module 1812 toward the motor 1818, thereby maneuvering the mechanism to the extended position 1842. The relative horizontal orientation of the single drive link 1810 at least partially contributes to the forward drive force applied to the pivot 1830 as the motor starter module 1812 slides toward the motor 1818. That is, because drive link 1810 maintains its generally horizontal orientation, the forward force distributed by motor starter module 1812 on pivot 1818 translates into a forward thrust force exerted by drive link 1810 on pivot 1830.

Pushing forward on the pivot 1830 from the closed position 1840 causes the corner brackets 1814 and 1816 to pivot clockwise on the pivot 1830 (based on the view provided in fig. 18D), thereby causing clockwise rotation of the initiator tube 350. As described elsewhere in this specification, clockwise rotation of the starter tube 350 causes extension of the pedal assembly. The extension of the pedal assembly is limited by the stop member 422 (fig. 4) such that engagement of the stop member 422 with the link 130 resists further rotation of the starter tube 350.

In one embodiment of the invention, the drive tube 350 is rotated a threshold number of degrees to adjust the seating unit from a standard position (e.g., 1840) to a TV position (e.g., 1842). For example, in one embodiment, drive tube 350 rotates at least about 104 degrees when adjusted from the folded position 1840 to the extended position 1842. In another embodiment, drive tube 350 rotates by an amount in the range of about 104 degrees to about 104.815 degrees. Naturally, when the threshold number of degrees is nearly constant (i.e., about 104 degrees), the operation of the linkage can be adjusted by adjusting the length of the angle brackets 1814 and 1816.

From the extended position 1842, actuation of the motor 1818 slides the motor starter module 1812 toward the motor 1818 to the reclined position 1844. Likewise, the drive link 1820 is in a generally horizontal orientation at position 1842 such that the force distributed by the motor starter module 1812 on the pivot 1828 translates forward to the pivot 1830, the corner brackets 1814 and 1816, and the portion on the starter tube 350. Because the starter tube 350 is prevented from further rotation in the reclined position 1844, forward movement of the drive link 1810 "drags" the corner brackets 1814 and 1816 forward along with the starter tube 350. Distributing forward force on the pivot 1830 from the extended position 1842 distributes forward force on the initiator tube 350. Referring also to fig. 18A, forward force on the initiator tube 350 is transferred to the seat plate 400, thereby causing the back mounting link 510 to rotate rearward and in a clockwise direction relative to the seat plate. In fig. 18D, the starter tube 350 is seen translating upward from the extended position 1842 to the reclined position 1844, the translated portion being guided by the front lift link 440.

According to one embodiment of the invention, the mounting tabs 1824 and 1826 extend rearward from the carrier body 1822 in a direction toward the back of the seating unit and toward the rear cross member 620. Extending the mounting tabs 1824 and 1826 in a rearward direction (opposite the extension toward the front of the seating unit and in a direction toward the front cross member 610) positions the aperture (i.e., pivot 1828) further rearward, thereby allowing the drive link 1810 to have a longer length between pivot 1828 and pivot 1830. In addition, extending the mounting tabs 1824 and 1826 toward the rear of the seating unit (opposite the front of the seating unit) increases the distance traveled by the motor activator module 1812, thereby increasing the stroke length of the linkage.

In an embodiment of the present invention, the length and longer stroke length of the drive link 1810, achieved by the rearwardly facing tabs 1824 and 1826, enables the linkage to move fully reclined (fig. 18A) and fully closed. The full recline may be defined in a variety of ways, and in one embodiment, the full recline is determined in part by the distance 1850 (fig. 18D) that the starter tube 350 moves horizontally from the closed configuration 1840 (fig. 3, 7, 8B, and 17A) to the reclined position 1844 (e.g., fig. 5, 8D, and 17C). In one embodiment, horizontal travel distance 1850 is in the range of at least about 8.9 inches to about 9.8 inches. For example, in the ganged configuration shown in FIGS. 17A-17C, the horizontal travel distance 1850 of the starter tube 350 is about 8.917 inches. In the ganged configuration shown in fig. 4-7, the starter tube 350 has a horizontal travel distance of about 9.793 inches. These relative horizontal travel distances are determined by various factors. For example, in the embodiment shown in FIGS. 17A-17C, the length of the corner brackets 1814 and 1816 is longer than the corner brackets 1814 and 1816 included in the embodiment of FIGS. 4-7.

Other measurements and dimensions may also be used to define a mechanism for properly adjusting between the closed position and the reclined position. For example, in one embodiment, the motor starter module 1812 includes a range of travel along the track 1820 of at least 14 inches. In yet another embodiment, the travel range is about 14.25 inches. In addition, drive link 1810 includes a distance between pivots 1828 and 1830 of at least 7 inches. In one embodiment, the distance between pivots 1828 and 1830 is about 7.2 inches. In yet another embodiment, the distance between the corner bracket 315 and the pivot 1830 is at least 2 inches, and preferably about 2.875 inches.

The drive link arrangement shown in fig. 18A-18D provides various cost-effective advantages. For example, the embodiment in fig. 18A-18D provides for material cost savings by including only a single drive link 1810, a single fastener between drive link 1810 and motor starter module 1812, a single fastener between drive link 1810 and corner brackets 1814 and 1816, and a single fastener between each corner bracket 1814 and 1816 and corner bracket 315. Furthermore, since there are fewer elements to be assembled, a saving in labor costs is achieved.

Referring now to fig. 8A and 9, an embodiment of a seat-mounting plate 400 will now be described. In one example, the seat-mounting plate 400 is provided with front and rear tabs, indicated by reference numerals 406 and 405, respectively. These tabs 405 and 406 are generally formed in the upper portion of the seat-mounting plate 400 to retain the seating structure (see reference numeral 12 of fig. 1-3). For example, the tabs 405 and 406 may be in a substantially perpendicular relationship with the rest of the seat-mounting plate 400. Thus, the tabs 405 and 406 of the seat-mounting plate 400 cooperate with similarly configured tabs of a complementary seat-mounting plate that is still in a substantially parallel spaced-apart relationship with the seat-mounting plate 400 to define a seat-supporting surface that extends between the seat-mounting plates.

In one exemplary embodiment, the seat-mounting plate 400 and the supplemental seat-mounting plate each include a one-piece seat shield 905 fixedly attached thereto. Typically, the seat shield 905 spans a section of the seating surface. As shown in fig. 9, the seat shield 905 includes a front end 911 and a rear end 912. The seat shield 905 may be fixedly attached to the front portion 901 of the seat mounting plate 400 at a front end 911 at a pivot 910 and may be fixedly attached to the rear portion 902 of the seat mounting plate 400 at a rear end 912 at a pivot 920. In operation, the seat shield 905 prevents the links of the linkage 100 from cutting into the foam, webbing, or other material comprising the seat of the seating unit.

Referring to fig. 9 and 10, the configuration and operation of the anti-tip mechanism 800 will now be described. First, the anti-tip mechanism 800 is typically mounted on an automated version of the invention (e.g., including the linear actuator 300) to prevent the seating unit from tipping forward when adjusted to the reclined position. When the user of the seating unit leans forward and the balance threshold (described above) is met, the manually adjustable linkages of fig. 1-7 and 17A-17C will naturally adjust from the reclined position to the extended position. However, this automated version remains stationary fixed in the reclined position as the user leans forward. This movement of the user's weight, combined with the weight of the forward movement of the extended footrest assembly 200, may unbalance the seat unit, causing the seat unit to tip forward. Accordingly, the anti-tip mechanism 800 extends forward in the reclined position to provide additional stability to the out-of-balance seating unit.

In general, anti-tip mechanism 800 includes a contact element 810, a rear component 830 having an upper end 831 and a lower end 832, and a front component 820 having an upper end 823, a lower end 821, and an intermediate section 822. The lower end 832 of the rear member 830 is rotatably coupled to the middle portion 417 of the base plate 410 at a pivot 801. An upper end 831 of the rear member 830 is pivotably coupled to an upper end 823 of the front member 820 at a pivot 802. The middle section 822 of the front member 820 is pivotally coupled to the middle section 458 of the front pivot link 450 at pivot 803. The lower end 821 of the front member 820 is coupled to the contact element 810 at pivot 804. As used herein, the term "contact element" 810 may generally refer to any member (e.g., plastic roller, rubber pad, etc.) that is capable of withstanding repeated contact with an underlying surface and is configured to be sufficiently rigid to promote stability of the seating unit.

In operation, the anti-tip mechanism 800 causes the contact element 810 to extend forward and downward toward a lower surface (not shown) when the linkage 100 is adjusted to the reclined position (see fig. 9). That is, when adjusted to the reclined position, the forward swinging of the front pivot link 450 about pivot 453 stretches the front member 820 such that the members 820 and 830 form an obtuse angle. In the opposite manner, when the linkage 100 is adjusted from the reclined position to the extended position (see fig. 10), the anti-tipping mechanism 800 retracts the contact element 810 away from the underlying surface. That is, when adjusted to the extended position, the rearward swing of the front pivot link 450 retracts the front member 820 such that the members 820 and 830 form an obtuse angle.

Referring to fig. 11-14 and 16, the sequence adjustment plate 550, the sequence adjustment element 560, and the front sequence adjustment link 570 will now be described. As with anti-tip mechanism 800, members 550, 560, and 570 are typically mounted on an automated version of linkage 100. One reason for mounting the members 550, 560 and 570 in an automated fashion is to correct for situations where the weight of the legs of the user of the seating unit causes the seat to rise and/or the backrest to recline out of sequence (i.e., before adjustment to the extended position is fully achieved).

As shown in fig. 11 and 16, the sequence adjustment plate 550 includes a guide slot 555, a hole 740 for receiving hardware for forming a pivot 551, and a hole 750 for receiving hardware for forming a pivot 556. The guide groove 555 is machined or formed in the sequence adjustment plate 550 and includes a first region 710, a second region 732, and an intermediate region 720 interconnecting the first region 710 and the second region 732. In an embodiment, the guide channel 555 is generally L-shaped, and the first region 710 is substantially vertical and the second region 732 is substantially horizontal.

Sequence adjustment plate 550 is rotatably coupled to the outside of rear bell crank 530. In one example, the rotatable coupling occurs at a pivot 551 located at a lower portion 537 (see fig. 6) of the rear bell crank 530. The rear end of the front sequence adjustment link 570 is pivotally coupled to the sequence adjustment plate 550 at pivot 556. The front end of the front sequence adjustment link 570 is pivotally coupled to the rear end 591 of the pedal drive link 590 at pivot 571 (see fig. 6). Thus, adjustment of the foot pedal drive link 590 between the closed position (see FIG. 12) and the extended position (see FIG. 13) in turn pivotally actuates the front sequencing link 570 laterally. This lateral actuation causes the sequence adjustment plate 550 to rotate forward and rearward about pivot 551. Thus, rotation of the sequence adjustment plate 550 changes the relative position of the sequence adjustment element 560 within the guide slot 555.

Typically, the sequencing elements 560 are configured as cannulas or cylindrical elements that can easily ride or travel within the guide slots 555. The sequence adjustment element 560 is fixedly attached to the middle 409 of the seat mounting plate 400 on the outside, which is the side opposite the rear bell crank 530. Typically, the sequencing elements 560 extend at least partially into the guide slots 555. In a particular embodiment, the sequence adjustment member 560 extends completely through the guide slot 555 and includes a cap (not shown) that retains the sequence adjustment plate 550 on the sequence adjustment member 560.

The interaction between the members 550, 560 and 570 will now be described. First, when the seating unit is adjusted to the closed position (see fig. 12), the sequence adjustment element 560 remains within the second region 732. When captured within the second region 732 of the guide slot 555, the interaction between the sequencing element 560 and the sequencing plate 550 blocks adjustment of the seating unit to the reclined position. However, when the seating unit is adjusted to the extended position (see fig. 13), the sequencing element 560 is displaced while still within the middle region 720 or elbow of the guide slot 555 by actuating the forward sequencing link 570 forward as described above. While still in the middle region 720, the seating unit may be freely adjusted to the closed or reclined position because the guide slots 555 allow for the sequential adjustment of the two directions of movement of the elements 560 from the middle region 720.

The seating unit may then be adjusted from the extended position to the reclined position (see fig. 14) via manual or automated control. This adjustment causes the seat mounting plate 400 to rise and displace the sequence adjustment element 560 while still within the first region 710. While the sequence adjustment element 560 is still within the first region 710 of the guide slot 555, interaction of the sequence adjustment element 560 and the sequence adjustment plate 550 blocks adjustment of the seating unit to the closed position. Accordingly, the above-described sequential adjustment ensures that adjustment of the foot pedal assembly 200 between the closed and extended positions is not interrupted by the rotational bias of the backrest, or vice versa. In other embodiments, the weight of the user of the seating unit and/or the springs interconnecting the links of the seat adjustment assembly 500 assist in forming or enhancing the sequential adjustment.

Referring to fig. 15, an exemplary configuration of the substrate 410 will now be described. First, the substrate 410 includes a front end 415 and a rear end 416 (see fig. 9). In addition, the substantially vertical curved portion 980 may constitute a lower edge of the substrate 410. In one exemplary embodiment, the base plate 410 has a step 960 that forms a bend 980 at its lower edge. The molding step 960 may be located at the front end 415 (not shown) of the base plate 410, at the back end 416 (see fig. 15) of the base plate 410, or both. As shown in fig. 15, the profiled step 960 may provide a raised section 970 fixedly attached to one of the cross members 610 or 620 of the cross member serving as the landing substrate.

Further, the raised section 970 may compensate for the height of the support sleeves 411 and 412, thereby allowing a majority of the bend 980 of the base plate 410 to remain at a height below the top of the support sleeves 411 and 412. In this way, the links of the linkage 100 can be designed to be longer and cover a wider swing (larger swing range) when pivoting. These longer length and wider swing features are beneficial in achieving more movement of the seat-mounting plate 400 and more wall clearance during recline of the back. In addition, the molding step 960 provides structural support and reinforcement to the ends 415 and 416 of the base plate 410, allowing the base plate 410 to be made of thinner sheet. In practice, the reinforced ends 415 and 416 of the substrate 410 resist bending, deformation, or other damage caused by dropping during transportation or by other common rough handling.

It should be appreciated that the configuration of the linkage 100 is adapted to enable the various links and brackets to be easily assembled and disassembled with other components of the seating unit. In particular, the nature of the pivot and/or mounting location allows for the use of quick disconnect hardware, such as a removable fastener. Accordingly, it is convenient to rapidly disconnect the members before transportation or to rapidly connect after reception.

The present invention has been described with reference to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments to which the invention relates will be apparent to those skilled in the art without departing from its scope.

From the foregoing, it will be seen that this invention is one well adapted to attain the ends and objects set forth above, together with other advantages which are obvious and inherent to the apparatus. It will be understood that certain features and partial combinations are practical and may be used without reference to other features and partial combinations. This is contemplated by and is within the scope of the claims. Those skilled in the art will appreciate that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, all matters set forth herein or shown in the accompanying drawings are to be interpreted as illustrative and not in a limiting sense.

Claims (5)

1. A seating apparatus for facilitating recline and tilt of a backrest, the seating apparatus comprising: a base plate having a front portion and a rear portion; a rear pivot link having a lower portion and an upper portion, the lower portion of the rear pivot link being pivotally attached to the rear portion of the base plate; a rear bell crank pivotally attached to an upper portion of the rear pivot link and pivotally attached to a seat mounting plate; a rear control link having a lower portion and an upper portion, the lower portion of the rear control link being attached to the rear bell crank and the upper portion of the rear control link being attached to a back mounting link, the back mounting link being attached to a back; a lap link having a rear portion and a front portion, the rear portion of the lap link being attached to the rear bell crank; a front lift link having a front portion, a rear portion, and a middle portion, the middle portion of the front lift link being attached to the front portion of the lap link and the rear portion of the front lift link being attached to the seat mounting plate; a front pivot link having an upper portion, a middle portion, and a lower portion, the upper portion of the front pivot link being attached to the front portion of the front lift link and the lower portion of the front pivot link being attached to the base plate; a bracket link having a front portion and a rear portion, the front portion of the bracket link being attached to a middle portion of the front pivot link; and a front bell crank having an upper portion and a middle portion, the upper portion of the front bell crank being attached to the rear portion of the bracket link and the middle portion of the front bell crank being attached to the seat mounting plate, wherein the bracket link includes a first pivot shaft that attaches the front portion of the bracket link to the front pivot link and a second pivot shaft that attaches the rear portion of the bracket link to the front bell crank, and wherein a distance between the first pivot shaft and the second pivot shaft is greater than or equal to 8 inches and less than or equal to 8.6 inches.

2. The seating apparatus of claim 1, wherein the rear pivot link comprises a first pivot for attachment to the rear bell crank and a second pivot for attachment to the base plate, the first pivot and the second pivot being spaced apart a first distance, and wherein the front pivot link comprises a third pivot for attachment to the front lift link and a fourth pivot for attachment to the base plate, the third pivot and the fourth pivot being spaced apart a second distance.

3. The seating apparatus of claim 2, wherein the first distance is in a range from 7 inches to 8.6 inches, and wherein the second distance is in a range from 8.5 inches to 10 inches.

4. The seating apparatus of claim 2, wherein a ratio of the first distance to the second distance is 7:8.5.

5. The seating apparatus of claim 2, wherein a ratio of the first distance to the second distance is 8.6:10.

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