CN116194017A - Disengagement and re-engagement mechanism for selective manual control on motorized seating units - Google Patents

Abstract

The present invention relates to a motorized positioning apparatus for a seating unit, the apparatus including a motor assembly configured to move a pair of linkages through a range of positions that place the seating unit in a stowed, open, or extended position. The motor assembly is selectively and releasably coupled to the linkage mechanism to allow a user to manually turn off the motor assembly and automatically couple via the coupling mechanism.

Description

Disengagement and re-engagement mechanism for selective manual control on motorized seating units

Background

Motorized movable furniture/movable furniture exists that moves an item of furniture, such as a seating unit (e.g., a recliner or a part of a modular seat), between a stowed position, an open position, or a TV position and a reclined position. These articles of furniture typically have a pair of metal linkages for controlling the positioning of the ottoman, seat and backrest. In the collapsed position, the seat is generally horizontal and the ottoman is stored in the collapsed position with the backrest generally upright. In the TV position, the ottoman is unfolded and the seat and backrest typically remain in their respective positions. In the reclined position, the ottoman is further extended, the seat can be moved forward and downward, and the backrest is reclined. In motorized versions of such furniture, the linear actuator or motor is connected to a linkage that controls the movement of the ottoman, seat, and backrest. By engaging the actuator, the article of furniture is moved between a plurality of positions, for example from a stowed position to a TV position and a reclined position (and back).

Typically, if a user of such a piece of movable furniture wishes to take the movable furniture out of operation (to return to its original shape), the user will engage an actuator (e.g., with a button or switch) to return the movable furniture to the stowed position. For example, if the user places the movable furniture in the TV position and wishes to exit the movable furniture, the user will press the appropriate button (possibly labeled "back" or "return" or "close") to engage the actuator, which moves the linkage to control the footrest, seat, and backrest as the movable furniture is returned to the closed position. However, the movement of the actuator may be somewhat slow. It would be useful and advantageous to allow a user to return movable furniture to a stowed position in a faster manual manner. As an example, if a user needs to answer a phone call located away from the movable furniture or needs to open a door, or if the user is simply impatient, the user may not want to wait for the actuator to return the movable furniture to the stowed position before the movable furniture is out of operation. It is advantageous and useful that the movable furniture is used in a motorized manner again even after the movable furniture has been manually returned to the stowed position.

Disclosure of Invention

One aspect of the present disclosure includes a motorized positioning apparatus for a seating unit that includes a motor assembly configured to move a pair of linkages through a range of positions that place the seating unit in a stowed, TV, or extended position. The motor assembly is selectively and releasably coupled to the linkage to permit the motor assembly to be selectively disengaged from the linkage to permit manual stowing of the seating unit by a user. The term "selectively and releasably coupled" may also be referred to as a selectively coupled state and a releasably coupled state, respectively. In some aspects, the drive block of the motor assembly is selectively coupled and decoupled from a motor tube, which is in turn coupled to a pair of linkages. In some aspects, a coupling mechanism, such as a solenoid, is used to control the pin to selectively couple and decouple the drive block from the motor tube.

Embodiments of the present disclosure are defined by the appended claims rather than this summary. To this end, a high-level overview of various aspects of the present disclosure is provided herein to provide an overview of the present 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.

Drawings

The present disclosure includes a number of details that may be referenced to the accompanying drawings, which are incorporated herein by reference, wherein:

FIG. 1 is a perspective view of a motorized multi-position seating unit with the seating unit in a stowed position, with one linkage not shown for clarity;

FIG. 2 is a view similar to FIG. 1 with the seating unit in the TV position, the ottoman having been moved to the extended position, and the backrest in the upright position;

FIG. 3 is a view similar to FIGS. 1 and 2 with the seating unit in a stowed position and the motor and drive block disengaged from the motor tube and linkage;

FIG. 4A is an enlarged view showing the drive block and motor disengaged from the motor tube and linkage;

FIG. 4B is a view similar to FIG. 4A showing the drive block disengaged from the motor tube and in a different position than FIG. 4A;

FIG. 5 is a view similar to FIG. 4A but showing the extension of the pin of the solenoid to couple the motor tube and linkage to the motor and drive block;

FIG. 6 is an enlarged view of the back plate, shaft insert, guide block and solenoid support;

FIG. 7 is an exemplary view of a motorized seating unit of the prior art;

FIG. 8 is a perspective view of an embodiment in which the control box automatically re-couples the drive blocks; and

fig. 9 is an enlarged view showing the drive block and motor disengaged from the motor tube and engaging the mounting bracket.

Detailed Description

The subject matter is described with specificity and detail in this disclosure in order to meet statutory requirements. The aspects described throughout this disclosure are intended to be illustrative, but not limiting, and the description itself is not intended to 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 disclosure, as well as in conjunction with other present or future technologies. Alternatives may become apparent to those of ordinary skill in the art to which the described aspects relate upon reading this disclosure without departing from the scope of the disclosure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This principle is considered by and within the scope of the claims.

An example of a prior art piece of movable furniture is shown and described in U.S. patent No. 9,845, 852 ("the' 852 patent"). By way of example, fig. 6 of the' 852 patent is shown here in a simplified manner as fig. 7, and shows one side of the movable furniture linkage in a collapsed position (text notes are added in fig. 7 for purposes of explanation). The side not shown is a mirror image of the side shown. The two linkages are coupled together, for example, by a fixed/stationary rail such as a rear base rail and/or a front base rail and a motor tube. Each end of the motor tube is coupled to a portion of the linkage. The motor tube is also coupled to an actuator. The actuator (or motor) may be engaged to move the drive block forward, causing the linkage to move from the stowed position to the TV position and then to the reclined position. The actuator may also be engaged to move the drive block rearward, causing the linkage to move from the reclined position to the TV position and then to the stowed position. In the prior art, the motor tube typically has a mounting bracket that is pivotably coupled to the drive block such that the motor tube always moves with the drive block, and thus the linkage always moves with the drive tube. The mounting bracket is pivotally coupled to the drive block, such as with a bolt or clevis pin. This connection is permanent, as the removal of the motor tube from the drive block requires access to the underside of the movable furniture, and typically requires some type of tool. In practice, this means that the only way to move the linkage between the stowed, TV and reclined positions is to activate an actuator or motor to move the drive block and motor tube, thereby moving the linkage. As noted above, in some cases, moving from the reclined position to the stowed position may take more time than the user wants.

Many aspects are contemplated in this application. As described above, the pair of linkages described herein may place the seating units in a stowed position, a TV position, or an extended position. The linkage may control the positioning of the ottoman alone, or the combined positioning of the ottoman, seat and backrest. The backrest and seat may be controlled by separate linkages in that the linkages may only control the positioning of the ottoman. Even in the aspect that the linkage mechanism only controls the positioning of the ottoman, the pair of linkage mechanisms can only arrange the ottoman in the collapsed position, the TV position, or the extended position.

Fig. 1 depicts a new coupling arrangement between the linkage and the actuator. More specifically, fig. 1 depicts motorized seating unit 10, showing linkage 12, with linkage 12 being operable to move motorized seating unit 10 from a stowed position (fig. 1) to a TV position (fig. 2) and a reclined position (not shown), and back. Another linkage of motorized seating unit 10 is not shown, but is a mirror image of linkage 12. The linkage 12 and the opposing linkage are coupled together at one point by a rear base rail 14, the rear base rail 14 typically being made of sheet metal bent or formed metal. Although a fixed rail, such as rear base rail 14, is shown in at least fig. 1 to couple the linkages together, in some aspects other fixed rails may be considered. The front base rail, which may be opposite the illustrated rear base rail, may couple the linkages together toward the ottoman end of the linkage 12. In some aspects, a combination of the front base rail and the rear base rail may couple the linkages together.

At another point, the linkage 12 and the opposing linkage are coupled together by a motor tube 16. Each end of the motor tube 16 is coupled to a portion of a respective linkage 12 such that when the motor tube 16 is moved, the linkage 12 moves the seating unit 10 between the stowed, TV, and reclined positions, and back.

A motor (e.g., an electric linear actuator) 18 is pivotally coupled to the rear base rail 14. For example, the rear motor mounting bracket 20 may be coupled to the rear base rail 14. Similarly, the motor housing 22 may have an integrally formed bracket 24, or the bracket 24 may be coupled to the motor housing 22. The bracket 24 and rear motor mounting bracket 20 may be pivotally coupled together, such as by passing a clevis pin 26 through holes in the bracket 24 and rear motor mounting bracket 20. Other attachment arrangements may also be used to pivotally couple the motor 18 to the rear base rail 14.

In some contemplated aspects, other fixed rails besides the rear base rail 14 may be pivotably coupled to the motor. It is contemplated herein that the motor 18 may be pivotably coupled to the front base rail, as described herein.

As best shown in fig. 2, the motor 18 is operable to move the drive block 28 along a body 30 of the motor 18. In one aspect, the motor 18 utilizes a worm gear rack arrangement to selectively move the drive block 28 forward or backward along the body 30. The body 30 may be pivotably coupled to a fixed rail, such as the rear base rail 14 or the front base rail described herein, along with the motor 18. In some other aspects, the body 30 couples the front base rail and the rear base rail.

As best shown in fig. 4B, the drive block 28 is coupled to a pair of mounting tabs 32, or the mounting tabs 32 may be integrally formed with the drive block 28. Each mounting tab 32 includes an aperture 34. The motor tube 16 has a mounting bracket 36 coupled thereto, such as by welding. The mounting bracket 36 has a pair of extensions, each having an aperture 38. The apertures 34 on the mounting tabs 32 and the apertures 38 on the brackets 36 are used to selectively couple the drive block 28 and motor 18 to the motor tube 16 and the linkage 12.

More specifically, as best shown in fig. 5 and 6, the back plate 40 is coupled to the motor tube 16. In some aspects, the back plate 40 is made of a sturdy material, such as metal, and includes a first set of elongated slots 42. In some aspects, slots 42 may be used to bolt back plate 40 to motor tube 16. In some aspects, the motor tube 16 may have corresponding threaded bores into which bolts 44 are threaded, or may have corresponding through holes in a nut-bolt connection arrangement. As best shown in fig. 6, in some aspects, the back plate 40 has a first opening section 46 and a second opening section 48. As best shown in fig. 4A, 4B and 5, the first opening section 46 allows the mounting bracket 36 (coupled to the motor tube 16) to extend through the first opening section 46 when the back plate 40 is coupled to the motor tube 16. In some aspects, the shaft insert 50 is also coupled to the back plate 40 just below the motor tube 16. The shaft insert 50 is also made of metal and has a generally u-shaped opening 52 formed therein, the opening 52 allowing clearance for the body 30 of the motor 18. In some aspects, the surface of the u-shaped opening 52 supports the body 30 of the motor 18. In some aspects, the guide block 54 is also coupled to the back plate 40 on a side of the back plate 40 opposite the shaft insert 50. In some aspects, the guide block 54 is also made of a metallic material. In some aspects, the shaft insert 50 and the back plate 40 may have aligned holes that are also aligned with threaded holes in the guide block 54. The bolts may then be passed through aligned holes in the shaft insert 50 and the backing plate 40 and threaded into threaded holes in the guide block 54 to couple the shaft insert 50, the backing plate 40, and the guide block 54 together. The guide block 54 also has an open channel 56 that transitions into a side guide surface 58 and a bottom guide surface 60. In some aspects, the open channel 56 corresponds to the size and shape of the second open section 48 in the back plate 40. The side guide surfaces 58 and the bottom guide surface 60 may be formed as inclined surfaces or chamfers.

Returning to the back plate 40, a first pair of adjustment slots 62 are cut or formed at one end of the back plate 40 and a second pair of adjustment slots 64 are cut or formed at the other end of the back plate 40. The first pair of adjustment slots 62 and the second pair of adjustment slots 64 extend vertically on the back plate 40. The first pair of adjustment slots 62 are used to couple a first solenoid bracket 66 to the back plate 40. The first solenoid bracket 66 has a first member 68 oriented orthogonally to a second member 70. The first member 68 and the second member 70 may be integrally formed, such as from sheet metal bends or angle irons. The first member 68 has a plurality of spaced apart threaded mounting holes 72 formed therein. In some aspects, the mounting holes 72 are positioned such that two mounting holes 72 are aligned with each slot in the first pair of adjustment slots 62. A bolt or other attachment mechanism may then be passed through the first pair of adjustment slots 62 and threaded into the mounting holes 72 to secure the first solenoid bracket 66 to the back plate 40. The first pair of adjustment slots 62 allow the first solenoid bracket 66 to be adjusted in a vertical direction on the back plate 40. The second member 70 of the first solenoid bracket 66 includes a pair of slots 74 that extend orthogonally from the plane of the back plate 40 when the first solenoid bracket 66 is coupled to the back plate 40.

As best shown in fig. 4A, the first solenoid 76 is supported on the first solenoid support 66 and is bolted or screwed to the first solenoid support 66, for example using slots 74. As best shown in fig. 5, the first solenoid 76 includes a first pin 78. The first solenoid 76 may be engaged to retract the pin 78 or disengaged to allow the pin 78 to extend from the first solenoid 76. The reverse is also true because the first solenoid 76 may be engaged to extend the pin 78 and disengaged to retract the pin 78. In either case, the first solenoid 76 is operable to actuate the pin 78, e.g., selectively extend and retract the pin 78.

Similar to the discussion above, as best shown in fig. 4A and 6, the second pair of adjustment slots 64 are used to couple the second solenoid bracket 80 to the back plate 40. The second solenoid bracket 80 has a first member 82 oriented orthogonal to a second member 84. The first member 82 and the second member 84 may be integrally formed, such as from sheet metal bends or angle irons. The first member 82 has a plurality of spaced apart threaded mounting holes 86 formed therein. In some aspects, the mounting holes 86 are positioned such that two mounting holes 86 are aligned with each slot in the second pair of adjustment slots 64. A bolt or other attachment mechanism may then be passed through the second pair of adjustment slots 64 and threaded into the mounting holes 86 to secure the second solenoid bracket 80 to the back plate 40. The second pair of adjustment slots 64 allow the second solenoid bracket 80 to be adjusted vertically on the back plate 40. The second member 84 of the second solenoid bracket 80 includes a pair of slots 88 that extend orthogonally from the plane of the back plate 40 when the second solenoid bracket 80 is coupled to the back plate 40. As best shown in fig. 5, the second solenoid 90 is supported on the second solenoid support 80 and is coupled to the second solenoid support 80 by bolts or screws, for example, using slots 88. The second solenoid 90 includes a second pin 92. The second solenoid 90 may be engaged to retract the pin 92 or disengaged to allow the pin 92 to extend from the second solenoid 90. The reverse is true because the second solenoid 90 can be engaged to extend the second pin 92 and disengaged to retract the second pin 92. In either case, the second solenoid 90 is operable to actuate the pin 92, e.g., selectively extend and retract the second pin 92.

As shown in fig. 1, the first solenoid 76 and the second solenoid 90 are coupled to a power source (not shown), a control box 93, and a controller 96. In one aspect, a release button 94 is added to a controller 96 of the motorized seating unit 10. The release button 94 is used to communicate a desired change in state of the first solenoid 76 and the second solenoid 90, as described further below. For example, the controller 96 may also have an on button 98 and an off button 100. In some aspects, the controller 96 is coupled to the control box 93, and the control box 93 receives signals from the controller 96 and communicates them to, for example, the motor 18, the first solenoid 76, and the second solenoid 90.

In the first state (as shown in fig. 1, 2 and 5), the first pin 78 of the first solenoid 76 and the second pin 92 of the second solenoid 90 extend through the corresponding apertures 34 on the mounting tab 32 and the corresponding apertures 38 on the bracket 36, thereby coupling the drive block 28 and motor 18 to the motor tube 16 and linkage 12. In this first state, operation of the motor 18 moves the drive block 28 forward, for example, when the user activates the on button 98, or operation of the motor 18 moves the drive block 28 rearward, for example, when the user activates the off button 100. For example, from the collapsed position shown in FIG. 1, the user may activate the open button 98 to move to the TV position of FIG. 2. Similarly, the user may activate the close button 100 to move from the TV position to the stowed position.

For example, if the motorized seating unit 10 is in the TV position of fig. 2, and the user wants to leave the motorized seating unit 10 faster than using the close button 100 (and waits for the motor 18 to move the drive block 28, motor tube 16, and linkage 12 to their respective stowed positions), the user can press the release button 94. This will change the state of the first and second solenoids 76, 90 to retract the first and second pins 78, 92 such that the first and second pins 78, 92 no longer extend through the corresponding apertures 34, 38 on the mounting tabs 32 and the brackets 36, thereby separating the drive block 28 and motor 18 from the motor tube 16 and linkage 12. In this second state, the user may apply a force to the ottoman link 102 (and corresponding ottoman, not shown) of the linkage 12 to manually move the linkage 12 and motorized seating unit 10 to the stowed position, as shown in fig. 3.

Note that in fig. 3, the drive block 28 is held in its position in the TV position of fig. 2, because the drive block 28 is separated from the motor drive tube 15. Upon actuation of the release button, the control box 93 communicates with the motor 18 to move the drive block 28 to the stowed position. Fig. 4B shows the drive block 28 slightly before returning to the stowed position, while fig. 4A shows the drive block 28 returning to the stowed position. When the linkage 12 is in the collapsed position (manually moved by the user), the corresponding apertures 34 on the mounting tab 32 and the corresponding apertures 38 on the bracket 36 are again aligned with the first and second pins 78, 92. When the drive block 28 reaches a position corresponding to the stowed position, the control box 93 sends a signal to the first solenoid 76 and the second solenoid 90 to return to the first state, moving the first pin 78 and the second pin 92 through the respective apertures 34 and 38 to re-couple the drive block 28 and the motor 18 from the motor tube 16 and the linkage 12 such that the open button 98 and the close button 100 are available to move the drive block 28 to move the linkage 12 and the seating unit 10 between the stowed position, the TV position, and the reclined position. Fig. 5 shows first and second pins 78, 92 extending through apertures 34, 38 to re-couple drive block 28 and motor 18 to motor tube 16 and linkage 12. In one aspect, the control box 93 may also signal the motor 18 to "jog (jog)" or slightly move the drive block 28 forward and then slightly rearward to ensure that the first and second pins 78, 92 have properly extended through the respective apertures 34, 38.

Although the first and second solenoids 76, 90 are described as moving the first and second pins 78, 92 through the apertures 34, 38, other coupling mechanisms may be used to selectively couple and decouple the drive block 28 and motor 18 from the motor tube 16 and the linkage 12 from a remote location (e.g., a button on the controller 96).

Other aspects of coupling between the drive block 28 and the motor 18 to and from the motor tube 16 and the linkage 12 (referred to as "coupling mechanisms") are also contemplated. In other embodiments described herein, each of the following aspects may be used to couple the motor 18 and the drive block 28 to and from the motor tube 16 and the linkage 12. Reference is made below to the various features shown in fig. 1 and 2.

One coupling mechanism may be a wrap-spring clutch for coupling the coupling mechanism to the actuator. In one aspect, a wrap spring clutch may be comprised of an input hub (hub) and an output hub that are attached to the motor 18 and the drive block 28, respectively, to move the drive block 28 forward or backward along the body 30. The helical wrap spring may span both hubs. The spring inner diameter may be slightly smaller than the outer diameter of the hub to form an interference fit. Rotating the input hub in the direction of the spring coil may force the spring to wrap down around the hub, thereby coupling the motor 18 and the drive block 28 without slipping. Stopping the motor 18 or reversing its direction may unwind the spring and release the output hub, allowing the drive block 28 to freely rotate (overrun). In other words, the wrap spring clutch may be unidirectional.

The other coupling mechanism includes a friction clutch. In one aspect, the friction clutch may be comprised of a receiving mechanism and an engaging mechanism that are attached to the motor 18 and the drive block 28, respectively, to move the drive block 28 forward or backward along the body. Engaging the receiving mechanism with the engagement mechanism may couple the receiving mechanism and the engagement mechanism, coupling the motor 18 to the drive block 28. In some aspects, engaging the receiving mechanism with the engagement mechanism may include rotating the engagement mechanism to engage the receiving mechanism. For example, the engagement mechanism may be threaded and rotated by the motor 18. In the same example, the receiving mechanism may be configured to receive a threaded engagement mechanism, thereby coupling the coupled motor 18 and drive block 28. In the same example, counter-rotating the engagement mechanism may disengage the engagement mechanism from the receiving mechanism. In other words, the friction clutch may be bi-directional.

Another coupling mechanism includes the use of a magnetic clutch. In one aspect, the magnetic clutch may be comprised of an armature and an output hub that are coupled to the motor 18 and the drive block 28, respectively. The output hub may include a magnetic mechanism, such as a field coil, configured to engage the armature. When the output hub is engaged, a magnetic field may be generated to couple the armature to the output hub, and thus the motor 18 and the drive block 28. The output hub can be disengaged, removing the magnetic field and separating the armature from the output hub. An electromagnet or a permanent magnet may be used to generate the magnetic field.

In one aspect, the coupling mechanism may be a residual magnetic clutch for coupling the coupling mechanism and the actuator. The residual magnetic clutch may be implemented to provide a residual magnetic force to engage the output hub and may store the magnetic force when the output hub is disengaged. In some aspects, the residual magnetic clutch may include a coil with a magnetizing current to generate a magnetic force to couple/couple the armature with the output hub.

In another aspect, a spring loaded clutch collet (collet) may be used as the coupling mechanism. In one aspect, a spring loaded clutch cartridge may include a circular drive member and a receiving member. Each of the circular drive and receiving members may be coupled to the motor 18 and drive block 28, respectively. The spring may be attached to the circular drive member and fit closely around the circular drive member. The receiving member may be configured to receive a spring, and similarly, the spring may fit tightly around the circular drive member. In some aspects, the spring is not coupled with the receiving member. The circular drive member may engage and couple the receiving member by rotating the coupled spring in the direction of the spring spiral via the motor 18. When the spring fits tightly around the receiving member, the spring may tighten and couple the circular drive member to the receiving member. The circular drive member may similarly be rotated in the opposite direction to disengage the spring from the receiving member. In this way, the spring loaded clutch can couple and decouple the motor 18 from the drive block 28.

In yet another aspect of the coupling mechanism, a sprag clutch may be implemented. The wedge clutch may include a drive unit and a receiving unit coupled to the motor 18 and the drive block 28, respectively. The receiving unit may comprise a plurality of non-rotating and asymmetric figure 8 wedges or some other unidirectional element. Each wedge may be slightly inclined when torque is applied in the opposite direction to the single direction. The receiving unit may be configured to receive the driving block while engaging the wedge. For example, the wedges may be slightly inclined when torque is applied in a clockwise direction, but each wedge may slip or freewheel when torque is applied in a counterclockwise direction. When the drive block is rotated clockwise by the motor 18, the wedges may tilt, preventing the drive block from disengaging the receiving unit. In this way, the wedge clutch can couple the linkage and the actuator.

In another aspect, the control box 93 may automatically re-couple the drive block 28. The control box 93 receives the position of the drive block 28. In some aspects, the control box 93 includes a plurality of sensors for determining the position of the drive block 28. In some aspects, a plurality of sensors may be in communication with the control box 93 to automatically re-couple the drive block 28.

Fig. 8 illustrates aspects in which the motor 18 and drive block 28 may be automatically re-coupled with the motor tube 16 and the linkage 12. As described herein, the drive block 28 may disengage in response to an input signal from the controller 96. The drive block 28 may be automatically re-coupled to the drive block 28 based on a position indication received by the control box 93 that the drive block 28 is in an aligned position with the linkage 12.

When the coupling mechanism is uncoupled, the drive block 28 is free to move relative to the linkage mechanism 12. The controller 96 may be in communication with the control box 93 to engage or disengage a coupling mechanism such as the first solenoid 76 and the second solenoid 90 or other coupling mechanisms described herein. The control box 93 can disconnect the coupling mechanism, disconnecting the drive block 28 from the linkage 12. When the drive block 28 is disengaged from the linkage 12, the user may manually move the linkage 12, such as to retract the linkage 12. For example, when drive block 28 is disengaged from linkage 12, a user may apply a force on linkage 12, such as at ottoman link 102 (depicted in fig. 2), to collapse linkage 12. When the linkage 12 is in the fully collapsed position, the drive block 28 may be in an aligned position with the linkage 12 and couple the connection mechanism. For example, the first and second pins 78, 92 are moved through the respective apertures 34, 38 to recouple the drive block 28 and motor 18 from the motor tube 16 and linkage 12, as shown in fig. 1-6.

The location indication may be received from a plurality of sources. As shown in fig. 8, a position indication is received from the first sensor 104 and/or the second sensor 106. As shown, the first sensor 104 is placed on or around the drive block 28 and the second sensor 106 may be placed on or around the motor housing 22. In some aspects, the second sensor 106 may be placed on the motor tube 16. The control box 93 may receive position indications from the first sensor 104 and the second sensor 106. The control box 93 may receive position indications from the first sensor 104 and the second sensor 106. In other words, the first sensor 104 and the second sensor 106 may communicate with the control box 93.

The control box 93 may determine the alignment position based on the received position of the first sensor 104 and/or the second sensor 106. The aligned position may indicate the position of the first sensor 104 and/or the second sensor 106 where the coupling mechanism may engage, coupling the drive block 28 to the motor tube 16. For example, the control box 93 may determine the alignment position by receiving a position indication from the first sensor 104 on the drive block 28 that the drive block 28 is at a distal position along the body 30 relative to the motor 18. The second sensor 106 may be on the motor tube 16 and indicate that it is at a proximate position along the body 30 relative to the motor 18. The control box 93 may determine that the motor tube 16 and the drive block 28 are not in a position where the coupling mechanism may be engaged to couple the motor tube 16 to the drive block 28. Conversely, when the control box 93 receives the position of the first sensor 104 (on the drive block 28) and the second sensor 106 (on the motor tube 16) at the same location along the body 30, such as at an approximate location along the body 30 relative to the motor 18, the control box 93 may engage the coupling mechanism.

In some aspects, the motor 18 may be a linear actuator with an integrated sensor (e.g., the second sensor 106). For example, the motor 18 may be a linear actuator, wherein extension of the motor may move the drive block 28 a substantial distance. The position of the drive block 28 may be determined by an indication of the position of the motor 18. On the other hand, the motor 18 is a worm gear rack arrangement, wherein the position of the drive block 28 may correspond to the number of revolutions of the motor 18. The motor 18 may send an indication of the rotation and/or position of the drive block 28 to the control box 93. The position of the drive block 28 may be determined from a position indication from the motor 18. In these aspects, the first sensor 104 may be placed on the motor tube 16. In these aspects, the control box 93 may be in communication with the motor 18 and the first sensor 104. The control box 93 may determine the alignment position by determining the position of the drive block 28 by the first sensor 104 on the motor 18 and motor tube 16.

The aligned position may not be a "aligned/consistent" position of the motor tube 16 and the drive block 28. As described herein, the aligned position may be a collinear position of the motor tube 16 and the drive block 28 where the coupling mechanism may be engaged and disengaged. In some aspects, the motor tube 16 and the drive block 28 may not be collinear, but rather offset, wherein the engagement coupling mechanism may slightly move the motor tube 16 and/or the drive block 28 to align the motor tube 16 and the drive block 28.

In some aspects, the first sensor 104 may be a proximity sensor (proximity sensor) to receive a location relative to the second sensor 106. In these aspects, the first sensor 104 may be placed on the drive block 28 and the second sensor 106 may be placed on the motor tube 16. For example, the first sensor 104 may be a proximity sensor that provides an alignment indication to the control box 93 when the second sensor 106 is within a specified distance.

The control box 93 may use any combination of the methods and systems described herein to determine the alignment position. The control box 93 may implement a computer device including a processor and memory to reference data storage of conditions (e.g., relative positions as described herein) of the first sensor 104 and/or the second sensor 106 indicative of an aligned position. Further, in some aspects, the control box 93 may be an electromechanical system in which the aligned positions form an electrical circuit to engage the coupling mechanism. In some further aspects, the control box 93 may be an electromechanical system in which the aligned position signals to engage the coupling mechanism.

In various aspects, the control box 93 may engage the coupling mechanism at various locations along the body 30. As described herein, the control box 93 may engage the coupling mechanism at an aligned position where the coupling mechanism may engage, coupling the drive block 28 to the motor tube 16. The alignment position may be at a midpoint along the body 30 or at any location along the body 30. The aligned position may be an approximated position along the body 30 relative to the motor 18 where the drive block 28 and motor tube 16 are fully drawn in, placing the linkage 12 in the collapsed position. In some embodiments, the drive block 28 and motor tube 16 must reach a particular location along the body 30 to engage the coupling mechanism. For example, the fully retracted position of the linkage 12 may position the motor tube 16 along the body 30 in an approximate position with the motor 18. In this example, the drive block 28 may be in an aligned position with the motor tube 16, with the motor tube 16 in an approximate position with the motor 18. In some aspects of this example, the control box 93 may only engage the coupling mechanism when the drive block 28 and the motor tube 16 are aligned in proximity.

In some aspects, the control box 93 may engage the coupling mechanism in the aligned position as the drive block 28 and/or motor tube 16 moves. In some aspects, a user or other external force may actuate the linkage 12 and the motor tube 16 may move along the body 30 when the linkage 12 is actuated. In these aspects, if the drive block 28 and motor tube 16 reach an aligned position during actuation of the linkage 12, the control box 93 may engage the linkage as the linkage 12 and/or the drive block 28 moves.

Other optional aspects are also contemplated. Fig. 9 illustrates a situation in which the mounting tab 32 may pull the mounting bracket 36 into the stowed position.

When the coupling mechanism is released (e.g., automatically or by a release button 94 shown and discussed in fig. 1), the drive block 28 may move freely along the body 30. As described above, the linkage 12 is free to move when released. In some aspects, it is contemplated that the linkage 12 may not be placed in the stowed position (as described with reference to fig. 8) when the coupling mechanism is released for manual adjustment.

The drive block 28 may contact the mounting bracket 36 to place the linkage 12 in the stowed position. The drive block 28 may contact the mounting bracket 36 by transferring (shifting) the drive block 28 to the mounting bracket 36. In some aspects, the drive block 28 may be moved along the body 30 beyond an aligned position (as described with reference to fig. 8) such that the mounting tabs 32 contact the mounting brackets 36. In some aspects, the mounting tab 32 may abut the mounting bracket 36. The drive block 28 may then be translated along the body 30 to the stowed position while moving the mounting bracket 36 and the linkage 12 to the stowed position.

Referring to fig. 8 and 9, in some aspects, the control box 93 may determine that the linkage 12 is not in the stowed position. The control box 93 may urge the drive block 28 into contact with the mounting bracket 36 to place the linkage 12 in the stowed position. In some aspects, the control box 93 may place the linkage 12 in the stowed position via a drive block prior to engaging the coupling mechanism.

In view of the above, the various aspects herein are well adapted to carry out all the objects and purposes set forth above, as well as other advantages which will be apparent from the structure itself. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible aspects may be made without departing from the scope of the invention, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

Claims (20)

1. A motorized positioning apparatus for a seating unit, the apparatus comprising: a pair of substantially mirror-imaged linkages having a plurality of links that control movement of the ottoman; a fixed rail coupled between a pair of linkage mechanisms; a motor tube coupled to at least one of the plurality of links of each linkage; a motor assembly including a main body coupled to the fixed rail and a driving block slidably penetrating the main body; a coupling mechanism for selectively and releasably coupling the drive block to the motor tube; and a control box for determining the positions of the drive block and the motor tube and engaging the coupling mechanism at a position where the drive block is coupled to the motor tube.

2. The motorized positioning apparatus of claim 1, wherein the coupling mechanism includes a back plate coupled to the motor tube and a pair of solenoid brackets to selectively and releasably couple the motor tube and the drive block.

3. The motorized positioning apparatus of claim 2, wherein the drive block includes a pair of mounting tabs having apertures; when the solenoid brackets are engaged, the pair of solenoid brackets actuate a pair of pins to be received by the apertures of the pair of mounting tabs; further, the pair of solenoid brackets selectively and releasably couple the motor tube to the drive block by actuating the pair of pins to be received by the apertures in response to an input signal.

4. The motorized positioning apparatus of claim 3, further comprising a controller, wherein the controller receives an input signal to disengage the coupling mechanism and separate the motor tube from the drive block.

5. The motorized positioning apparatus of claim 2, wherein the back plate includes a pair of adjustment slots extending vertically on the back plate to receive and couple the pair of solenoid brackets at a position to selectively and releasably couple the motor tube to the drive block.

6. The motorized positioning apparatus of claim 2, wherein the back plate includes an opening to receive and support the body of the motor.

7. The motorized positioning apparatus of claim 1, wherein the motor assembly includes a worm gear rack arrangement to slidably move the drive block through the body.

8. The motorized positioning apparatus of claim 1, wherein the coupling mechanism coupling the drive block to the motor tube and the stationary rail comprises at least one of a friction clutch, a sprag clutch, a spring-loaded clutch, a magnetic clutch, a residual magnetic clutch, or a friction clutch.

9. A motorized positioning apparatus for a seating unit, the apparatus comprising: a pair of substantially mirror-imaged linkages having a plurality of links that control movement of the ottoman; a fixed track coupled between a pair of substantially mirror-image linkages; a motor tube coupled to at least one of the plurality of links of each linkage; a motor assembly including a main body coupled to the fixed rail and a drive block slidably penetrating the main body, the drive block including a mounting bracket; a coupling mechanism coupled to the motor tube and selectively coupled to the mounting bracket, wherein engaging the coupling mechanism couples the coupling mechanism to the mounting bracket; and a control box for receiving a position of the mounting bracket relative to the coupling mechanism, determining the position indicating alignment of the mounting bracket with the coupling mechanism, and engaging the coupling mechanism with the mounting bracket based on the determination of alignment of the mounting bracket with the coupling mechanism.

10. The motorized positioning apparatus of claim 9, further comprising a fixed track coupled between a pair of substantially mirror image coupling mechanisms.

11. The motorized positioning apparatus of claim 9, wherein disengaging the coupling mechanism separates the coupling mechanism from the mounting bracket; the motorized positioning apparatus also includes a controller for receiving an input signal, and the input signal received by the controller disengages the coupling mechanism from the mounting bracket.

12. The motorized positioning apparatus of claim 9, wherein the motor assembly comprises a motor operable to move the drive block along the body.

13. The motorized positioning apparatus of claim 9, wherein the coupling mechanism includes a pair of solenoid brackets including a pair of pins, and engaging the coupling mechanism includes engaging the pair of pins receivable by the apertures of the mounting bracket.

14. The motorized positioning apparatus of claim 9, further comprising a back plate coupled to the motor tube, wherein the back plate couples the coupling mechanism to the motor tube, and the back plate includes an opening to receive the body.

15. The motorized positioning apparatus of claim 14, wherein the back plate is slidably movable along the body to move the motor tube and the pair of mirrored linkages to control the movement of the ottoman.

16. A motorized positioning apparatus for a seating unit, the apparatus comprising: a pair of substantially mirror-imaged linkages having a plurality of links controlling movement of the ottoman, the backrest and the seat; a rear base rail coupled between the pair of linkages; a motor tube coupled to at least one of the plurality of links of each linkage; a motor assembly including a main body coupled to the rear base rail, a drive block, a mounting bracket including an aperture, and a motor coupled to the drive block to enable sliding movement of the drive block along the main body; a coupling mechanism coupled to the motor tube and selectively coupled to the mounting bracket, wherein disengaging the coupling mechanism separates the coupling mechanism from the mounting bracket using the aperture and engaging the coupling mechanism couples the coupling mechanism to the mounting bracket; a controller for receiving an input signal, wherein the received input signal disengages the coupling mechanism from the mounting bracket at a first location along the body; and a control box for engaging the coupling mechanism with the mounting bracket at a second location along the body.

17. The motorized positioning apparatus of claim 16, wherein the second position is an approximated position along the body relative to the motor assembly, and the first position is a distal position along the body relative to the motor assembly.

18. The motorized positioning apparatus of claim 16, wherein the selectively coupled state is capable of moving the drive block along the body to move the motor tube and actuate the pair of substantially mirror-image linkages.

19. The motorized positioning apparatus of claim 16, wherein the control box receives an indication of the position of the mounting bracket along the body and engages the coupling mechanism when the control box receives an indication of the mounting bracket in the second position.

20. The motorized positioning apparatus of claim 16, wherein the control box receives an indication of a status from the motor assembly, the status corresponding to a position of the mounting bracket along the body, and the coupling mechanism is engaged when the control box receives an indication of a status of the motor assembly corresponding to the second position.

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