Abstract:
A reclining chair system that features a recliner motion mechanism used for positioning a reclining unit that includes a seat and a seat back having a fixed positional relationship to each other, including a gear rack adapted to receive a gear that travels in engagement with the gear rack, a gear shaft attached to the gear and driven by a drive motor for rotating the gear and causing it to move along the gear rack, a connection between the drive motor and seat that causes the seat back to move, as the gear travels along the gear rack, at least at the seat back&#39;s lower edge, and generally in the direction of the gear rack, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the seat back at a position for causing a rotational movement of the seat back relative to a rotational axis of the gear, to guide the seat back during movement of the gear along the gear rack.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to furniture. More particularly, this invention relates to furniture and apparatus, and methods for making the same, for positioning individuals in relaxing, comfortable, and/or healthful positions.  
       BACKGROUND OF THE INVENTION  
       [0002]     The term zero gravity positioning relates to the orientation of the legs above the level of the heart. It is also called the “90-90” position and the Trendleberg position. The latter term is commonly used in hospitals when a bed is positioned with the legs elevated in order to reduce tension and improve blood circulation. The term “zero gravity,” or “Z.G.,” stems from suggestions that the human body naturally assumes a similar orientation with respect to the legs when relaxed and suspended in weightlessness.  
         [0003]     Chairs have existed since prehistoric times, and recliners have been manufactured for centuries. More recently, relatively speaking, chairs that pivot and chairbacks that fold have been developed. Another improvement consists of some form of leg support while a chair is in a reclined position.  
       SUMMARY OF THE INVENTION  
       [0004]     A family of reclining chair systems has been developed that features, in one aspect, a recliner motion mechanism used for positioning a recliner that includes a seat and a seat back having a fixed positional relationship to each other. According to various embodiments of the present invention, the recliner motion mechanism includes the following: a gear rack adapted to receive a gear that travels in engagement with the gear rack, a gear shaft attached to the gear and driven by a drive motor for rotating the gear and causing it to move along the gear rack, a connection between the drive motor and seat that causes the seat back to move, as the gear travels along the gear rack, at least at the seat back&#39;s lower edge, and generally in the direction of the gear rack, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the seat back at a position for causing a rotational movement of the seat back relative to a rotational axis of the gear, to guide the seat back during movement of the gear along the gear rack.  
         [0005]     According to various embodiments, the invention also includes a gear rack and the curved track adapted to move the seat and seat back into a zero gravity position, wherein the gear is positioned by the motor at a greater distance from a recliner base when the seat back is in a generally reclined position than when the seat back is in a generally upright position, and wherein the motor is powered by a battery. It will be understood by persons versed in the field that the motor may alternatively be powered, for example, using a power cord that plugs into a power outlet. Moreover, in embodiments using a power cord, for example, various precautions may be taken to prevent the undesirable winding of the cord around the chair.  
         [0006]     Other embodiments include one or more of the following features. A base unit that supports a seat, wherein the base unit does not recline, the seat has a center of gravity, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position, a motive drive including a motor that operates to move the center of gravity of the seat forward when shifting the unit to the reclined position, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the back support member to guide the back support member down during forward movement of the center of gravity of the seat, wherein the motive drive and the curved track are adapted such that the reclined position is a zero gravity position and wherein the motor is positioned at a higher altitude level when the reclining unit is in the reclined position than when the unit is in the generally upright sitting position. A swivel mechanism is provided to permit the base unit to pivot at least partially, and preferably 360°, around a vertical axis. A battery is preferably provided to power the motive drive.  
         [0007]     In still other embodiments, a reclining chair further includes a base unit that supports a seat, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position, a motive drive element that operates to move the reclining unit from the generally upright sitting position to the reclined position, and a fixed track guide element, the motive drive element and the fixed track guide element adapted to permit a rotation of the reclining unit with a simultaneous forward translation of the reclining unit when the reclining unit is moving from the generally upright sitting position to the reclined position, wherein the base unit is adapted to permit the unit to pivot at least partially around a vertical axis.  
         [0008]     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from accompanying drawings, in which like reference characters refer to like parts throughout, and from the following detailed description and claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is an illustration of a recliner according to an embodiment of the present invention.  
         [0010]      FIG. 2  is a partial side view of a recliner in an upright position according to an embodiment of the present invention.  
         [0011]      FIG. 3  is a partial side view of the recliner shown in  FIG. 2  in a partially reclined position according to an embodiment of the present invention.  
         [0012]      FIG. 4  is a partial side view of the recliner shown in  FIGS. 2 and 3  in a zero gravity position according to an embodiment of the present invention.  
         [0013]      FIG. 5  is a partial side view of armrest and motion bracket assemblies according to an embodiment of the present invention.  
         [0014]      FIG. 6  is a partial front view of motion bracket, armrest, and motor assemblies according to an embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0015]     Referring to  FIG. 1 , an example of an architecture in accordance with an aspect of the invention is depicted generally at  100 . The system architecture includes a seat, seat back, and footrest member  110 , wherein the seat, seat back and armrest have a fixed positional relationship to one another. Member  110  can be positioned in an upright position and reclined to a zero gravity position. Member  110  is supported by armrests  120  and by a base  130 . In this example, the armrests  120  do not move as member  110  is reclined. Member  110  and the armrests  120  can pivot side-to-side on base  130  about a vertical axis. Member  110  and armrests  120  are upholstered in the view displayed in  FIG. 1 .  
         [0016]     Referring to  FIG. 2 , a side view of an embodiment of the invention in an upright position is shown. The upholstery is omitted in the drawing. A backrest frame  205  is constructed using a preferably rigid material (e.g., tubular steel) with an “S” shape to provide a user back support while upright and in the reclined Z.G. position. Backrest frame  205  is connected to a motion bracket  206 , which in turn connects to a seat and footrest frame  207 . In various embodiments, motion bracket  206  is also constructed using a rigid material such as steel.  
         [0017]     According to various embodiments of the invention, the connection of backrest frame  205  to motion bracket  206 , and the connection of motion bracket  206  to footrest frame  207 , may be permanent and/or made before the recliner chair is purchased by a user. According to other embodiments, these components may be detachably connected to one another prior to purchase. In yet other embodiments, these components may be either detachably or permanently connected by a user following the purchase of the chair (e.g., in the convenience of the user&#39;s home). In this last case, as will be appreciated by those versed in the field, transport of the partially unassembled recliner chair will generally be easier than if the chair was constructed prior to transport (e.g., by a merchandiser or manufacturer prior to the purchase of the recliner chair). Additionally, in this case, separate upholstery can be added by, e.g., the manufacturer or the user, for many or all of the various parts of the recliner chair (e.g., the backrest frame  205 , the seat of the recliner chair, the footrest frame  207 , the armrest  220 , etc).  
         [0018]     Moreover, according to the invention, footrest frame  207  is designed for easy access to and from the chair. Mounted to motion bracket  206  is a motor  211 . Motor  211  drives a shaft attached to a gear  213 , which moves along a straight rack  215  within the armrest  220 . According to various embodiments of the invention, straight rack  215  is made of a rigid material, such as steel. In the embodiment of the invention illustrated in  FIG. 2 , straight rack  215  is positioned at a 33° incline, which is important but not unique in achieving Z.G. positioning. It will be understood by persons versed in the field that other angles of incline can be used without departing from the principles of the present invention.  
         [0019]     When gear  213  is positioned at the bottom of straight rack  215  as illustrated in  FIG. 2 , backrest frame  205  and footrest frame  207  are oriented in the upright sitting position. By moving gear  213  along straight rack  215  to a position  221 , backrest frame  205  and footrest frame  207  are reclined to a Z.G. position (vide  FIG. 4 ). Motion bracket  206  also has mounted a wheel or follower  223 , which engages a curved track  225  that forms part of armrest  220 . Follower  223  guides and supports backrest frame  205  and footrest frame  207  as motor  211  positions them in sitting or reclined positions.  
         [0020]     As the seat moves down curved track  225 , and up rack  215 , the backrest is reclined following the arch of curved track  225 . The end points of curved track  225  and straight rack  215  are important as they define the two key positions of the zero gravity recliner. The particular shape of curved track  225  dictates the amount and speed of travel from a fully upright to a fully reclined position. Armrest  220  also includes a “V” shaped section  227  of the carriage, and a tubular cross member  228  of the carriage. Member  228  connects with a swivel point  229 , about which the seat can pivot up to 360° (or more) on base  230 . In this example, base  230  is a domed circular disk formed of cast aluminum or other suitable material. The pivoting action at base  230  is achieved by a swivel mechanism  235 . A side panel  240  (constructed from, e.g., wood) hides the working parts of armrest  220  and bolts on to V section  227  of the carriage at, in this illustrative embodiment, three attachment points. The remaining four attachment points, one of which is indicated as attachment point  242  in  FIG. 2 , is used, for example, to hold center section  551  shown in  FIG. 5  in place.  
         [0021]     Referring to  FIG. 3 , a side view of the embodiment of the invention illustrated in  FIG. 2  is shown in a partially reclined position. Straight rack  215 , armrest  220 , curved track  225 , V section  227  of the carriage, member  228  of the carriage, swivel point  229 , base  230 , swivel mechanism  235 , wooden side  240 , and attachment point  242  have not changed positions in  FIG. 3  compared to their respective positions shown in  FIG. 2 . However, motor  211  has positioned gear  213  further up straight rack  215 , resulting in a forward translation and a rotation of motion bracket  206  as the wheel or follower  223  moves down along curved track  225 ; here, follower  223  is illustrated at the mid-point of curved track  225 . In this position, the backrest frame  205  is partially reclined, and seat and footrest frame  207  has, relative to the upright position, rotated the user&#39;s thighs upward and lifted his legs off the floor.  
         [0022]     Referring to  FIG. 4 , a side view of the embodiment of the invention illustrated in  FIGS. 2 and 3  is shown in the zero gravity position. Straight rack  215 , armrest  220 , curved track  225 , V section  227  of the carriage, member  228  of the carriage, swivel point  229 , base  230 , swivel mechanism  235 , wooden side  240 , and attachment point  242  have not changed positions in  FIG. 4  compared to their respective positions shown in  FIGS. 2 and 3 . However, motor  211  has positioned gear  213  to the top of straight rack  215  and follower  223  has moved to the bottom of curved track  225 . Motion bracket  206  has moved to its forwardmost position (i.e., to the furthest point left looking from the side in  FIG. 4 ). Backrest frame  205  is reclined, and the footrest and seat frame  207  is positioned to place the user&#39;s legs almost horizontally and above the level of the user&#39;s heart.  
         [0023]     The recliner described herein can be placed in many (e.g., in essence, an infinite number of) positions between the upright and reclined positions shown in  FIGS. 2 and 4 , respectively. The follower  223  in the curved track  225  defines the motion of the chair, the starting and ending points, and the rate of recline; too slow can be frustrating for the user and too fast can cause physical issues for some people.  
         [0024]     The upright position shown in  FIG. 2  allows the Z.G. recliner to be more than just a recliner, but also an upright chair suitable for reading or conversing comfortably. This functionality requires good support and seating angles when upright, which necessitates mechanical strength, balanced motion, and added physical space greater than in traditional Z.G. recliners.  
         [0025]     The starting point for this chair, in the illustrated embodiment shown in  FIG. 2 , with the follower  223  at the top of the curved track  225 , is with a slightly forward pitched seat. This seat angle makes entrance and exits from the chair easy; it is possible to slide in and out. This is particularly beneficial for users (e.g., those with back pain) that have trouble positioning themselves into, and getting out of, traditional recliner chairs. To further aid with this movement, the arms are far forward, and an indent in the sides allows for an easy grip. Additionally, in various embodiments of the invention, base  230  and/or other components described herein are constructed such that the seat is situated at an elevated level compared to conventional recliner chairs. This also facilitates use of the chair by users. The follower  223  then moves along the curved track  225 , which is pitched downward at a steep angle. This is to move the backrest quickly into recline and settle the user into the backrest. As the backrest approaches the mid-reclined position, the curve angles forward so the seat rises quickly and the footrest moves up. The final positioning moves the footrest above the level of the heart, though the back does not recline further.  
         [0026]     The straight rack  215  and direct drive in this new design provides the mechanical power for this chair within a small amount of space. The angle of the straight rack  215  speeds the lifting of the seat and the user&#39;s legs, reduces slightly the space requirements, and reduces stress on the motor  211  when returning from the Z.G. reclined position.  
         [0027]     Referring to  FIG. 5 , a side view illustration of the armrest and motion bracket assemblies in one embodiment of the invention is shown. Ergonomic considerations include a curved armrest pad  555 , designed for use in both the upright and reclined positions, and the forward design of a front grip  557 , which permits ease of access to the seat. A center section  551  is designed for ease of assembly of the mechanical components, including assembly of motion bracket  506  (constructed from, e.g., steel), gear  513 , and tubular member  528  of the carriage. Member  528  includes swivel point  529 , and a battery used to power the drive motor is located in a battery housing  550 . Alternatively, an electrical connection to an alternate source of power can be provided. A side panel  540  (constructed from, e.g., wood) is also included, which as described above in connection with panel  240  of  FIG. 2 , hides various working parts. In  FIG. 5 , the components are shown for the upright position, with follower  523  at the top of curved track  525  and gear  513  at the lowest position on straight rack  515 .  
         [0028]     Referring to  FIG. 6 , a front view illustration of the assemblies of  FIG. 5  is shown. Tubular member  628  of the carriage is shown, as is the swivel point  629  to which a “Cornet” swivel mechanism (or other suitable type of swivel mechanism) attaches. As can be seen in  FIG. 6 , motion bracket  606  includes attachment flange  665  to which the seat and footrest frame are attached, and attachment flange  670  to which the backrest frame is attached. Followers  623  are shown extending from the motion bracket  606 , and have a “wheel” or bushing attached that engages the curved track that is formed within the center section  660  that is made from wood or other suitable material according to the invention. Attached to the center span of motion bracket  606  is a motor assembly  675 , which includes a motor  677  that drives a shaft attached to the gear (not shown) to move the bracket assembly. The spur gear and its axel slide through a slot  679  to attach to motor assembly  675 . The wooden side panel (not shown), which can be upholstered, attaches to the outside of wooden center section  660  to hide the mechanical assemblies.  
         [0029]     While there have been shown and described examples of the present invention, it will be readily apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined by the following claims. Accordingly, the invention is limited only by the following claims and equivalents thereto.