Stop mechanism for recliner chair

A reclining mechanism for a seating unit including a base, a linkage mechanism operatively coupled to the base, the linkage mechanism configured to move between a closed position and one or more open positions, and a stop member configured to contact the linkage mechanism and the base when the linkage mechanism is in the closed position. The linkage mechanism may include a forward pivot link pivotally connected to the base. The stop member may include a pin coupled to one of the base and the forward pivot link and may contact the other of the base and the forward pivot link when the linkage mechanism is in the closed position.

BACKGROUND

Recliners are generally well known in the furniture industry. The term recliner is used throughout this description to describe articles of furniture that include a reclining mechanism. Generally, recliners are chairs that allow the user to recline and are equipped with extendable footrests. Recliners are often in the form of a plush chair, however, they might also take the form of an oversized seat, a seat-and-a-half, a love seat, a sofa, a sectional, and the like. Recliners are known in both a manual configuration (where the user releases the reclining mechanism from a closed position to a TV position, and moves the reclining mechanism from the TV position to a full recline position) and a motorized version (where a motor is used to move the mechanism between the various positions).

The reclining motion is achieved in recliners with a linkage mechanism that is coupled to a base. The linkage mechanisms found in recliners in the art include a plurality of interconnected links that provide one or more mechanisms for extending a footrest, reclining the recliner, and obstructing movements of the chair when in specific orientations. Typically, recliners known in the art provide three positions: an upright seated position with the footrest retracted beneath the chair (the “closed position”); a television viewing position in which the chair back is slightly reclined but still provides a generally upright position with the footrest extended (the “TV position”), and a full-recline position in which the chair back is reclined an additional amount farther than in the TV position but still generally inclined with respect to the seat of the chair and with the footrest extended (the “fully reclined position”).

These types of prior art recliner mechanisms, while functional, suffer from a number of drawbacks. One of which includes a problem with slack in the linkage mechanism when the chair is in the closed position. Slack in the linkage mechanism results in movement of various portions of the chair (e.g., seat and/or back) when a user sits in the chair in the closed position. It would be desirable to provide a recliner, whether manual or motorized, having an improved stop mechanism that reduces slack in the linkage mechanism when the chair is in the closed position.

BRIEF SUMMARY

At a high level, this disclosure relates to an improved stop mechanism for recliners. The improved stop mechanism reduces slack in the linkage mechanism when the chair is in the closed position. The stop mechanism may include a pin coupled to the linkage mechanism or the base and a mating stop surface formed on the other of the linkage mechanism or the base opposite the pin. When the chair is in the closed position, the pin contacts the mating stop surface and halts further movement of the linkage mechanism in a first direction. The stop mechanism may further include one or more additional pins coupled to various portions of the linkage mechanism and paired with one or more additional mating stop surfaces formed on various other portions of the linkage mechanism. When the chair is in the closed position, the one or more additional pins each contact a respective mating stop surface of the one or more additional mating stop surfaces and halts further movement of the linkage mechanism in the first direction.

In an embodiment of the invention, a recline mechanism for use in reclining furniture is described. The recline mechanism may include a base, a linkage mechanism, and a stop member. The linkage mechanism may be operatively coupled to the base and configured to move between a closed position and a plurality of open positions. The stop member may be configured to contact the linkage mechanism and the base when the linkage mechanism is in the closed position and prevent relative motion in a first direction between the linkage mechanism and the base.

The linkage mechanism may include a forward pivot link and a rear pivot link. The forward pivot link and the rear pivot link may be pivotally coupled to the base. In some aspects, the stop member may be coupled to the forward pivot link and configured to contact the base when the linkage mechanism is in the closed position. The base may include a mating stop surface configured to contact the stop member when the linkage mechanism is in the closed position. In other aspects, the stop member may be coupled to the base and configured to contact the forward pivot link when the linkage mechanism is in the closed position. The forward pivot link may include a mating stop surface configured to contact the stop member when the linkage mechanism is in the closed position.

In another embodiment, a recliner is described. The recliner may include a right base, a left base, a linkage mechanism, and one or more stop members. The linkage mechanism may be coupled to the right base at a right forward pivot link and a right rear pivot link. The linkage mechanism may be coupled to the left base at a left forward pivot link and a left rear pivot link. The linkage mechanism may be configured to move between a closed position and a plurality of open positions. The one or more stop members are configured to contact the linkage mechanism and contact one of the right base and the left base when the linkage mechanism is in the closed position.

The one or more stop members may comprise a right stop member and a left stop member. The right stop member may be configured to contact the right forward pivot link and the right base and the left stop member may be configured to contact the left forward pivot link and the left base when the linkage mechanism is in the closed position. The right stop member may be a right stop pin coupled to the right forward pivot link. The right stop pin may be configured to contact a right mating stop surface formed on the right base when the linkage mechanism is in the closed position. The right mating stop surface may be integrally formed on the right base. The right stop member may comprise a right stop pin coupled to the right base and configured to contact a right mating stop surface formed on the right forward pivot link when the linkage mechanism is in the closed position. The left stop member may comprise a left stop pin coupled to the left forward pivot link and configured to contact a left mating stop surface formed on the left base when the linkage mechanism is in the closed position. In other aspects, the left stop member may comprise a left stop pin coupled to the left base and configured to contact a left mating stop surface formed on the left forward pivot link when the linkage mechanism is in the closed position.

In another embodiment of the invention, a recline mechanism for use in reclining furniture is described. The recline mechanism may include a base, a forward pivot link pivotally connected to the base, and a pin configured to stop the rotation of the forward pivot link relative to the base when a linkage mechanism is in a closed position. The forward pivot link may be configured to rotate and cause the linkage mechanism to move between the closed position and a plurality of open positions. The pin may be coupled to one of the base and the forward pivot link and contacts the other of the base and the forward pivot link when the linkage mechanism is in the closed position.

The pin may contact a mating stop surface. The mating stop surface may be integrally formed on one of the base and the forward pivot link. In some aspects, the pin may comprise a first pin, and the mating stop surface may comprise a first mating stop surface. In such aspects, the recline mechanism may further comprise a second pin, a second mating stop surface, a third pin, and a third mating stop surface. The second pin and third pin may each be coupled to the linkage mechanism. The second mating stop surface and the third mating stop surface may each be formed on the linkage mechanism. The second pin may contact the second mating stop surface when the linkage mechanism is in the closed position. The third pin may contact the third mating stop surface when the linkage mechanism is in the closed position.

The linkage mechanism may include a bell crank, a connector link, a rear lift link, and a seat plate. The second pin may be coupled to the rear lift link. The second mating stop surface may be formed on the seat plate. The third pin may be coupled to the bell crank. The third mating stop surface may be formed on the connector link. The linkage mechanism may further include a front lift link and a seat plate. The recline mechanism may further include a fourth pin and a fourth mating stop surface. The fourth pin may be coupled to the front lift link. The fourth mating stop surface may be formed on the seat plate. The fourth pin may contact the fourth mating stop surface when the linkage mechanism is in the closed position.

DETAILED DESCRIPTION

Referring to the drawings generally, a portion of a recline mechanism of a recliner is shown in a closed position in accordance with an embodiment of the invention. The recline mechanism couples together a footrest, chair back, chair arms, and a chair seat of a recliner. For the sake of clarity, these portions of the recliner are not shown. The recline mechanism may include a linkage mechanism coupled to a base. Often, the recline mechanism includes a pair of linkage mechanisms (e.g., a left linkage mechanism and a right linkage mechanism) coupled to the base. For clarity, only one linkage mechanism is shown in the figures. In aspects with a pair of mechanisms, the side not shown may be a mirror image of the side that is shown. The illustrated recline mechanism is a manual recline mechanism where a user causes the recliner to move from the closed position to one of a plurality of open positions (e.g., the TV position or the fully reclined position). The following description, however, applies equally to a motorized recline mechanism.

Turning now toFIG. 1, an exemplary recline mechanism is illustrated having a linkage mechanism26pivotally coupled to a base10. The base10may comprise a base rail12formed from angle steel, as in the illustrated aspect. The base rail12supports the linkage mechanism26and the remainder of the chair above the surface on which the recliner is placed. In aspects where the recline mechanism includes a pair of linkage mechanisms26, the base10may include a pair of spaced apart base rails12coupled to the pair of linkage mechanisms26. One or more cross-members may connect portions of the base10and/or the pair of linkage mechanisms26. In some aspects, the cross-members are made from angle steel or tubular steel.

An exemplary linkage mechanism will now be described. In the illustrated embodiment ofFIGS. 1 and 2, the linkage mechanism26is pivotally coupled to the base rail12through a front pivot link28and a rear pivot link30. The front pivot link28and the rear pivot link30each may rotate generally in direction A to move the recline mechanism from the closed position (shown inFIGS. 1 and 2) to the one or more open positions (e.g., the TV position, the fully-reclined position, or any other open position). The rear pivot link30extends upward from the base rail12. The rear pivot link30, like the remainder of the links described below, is typically made from steel. The upper, forward end of the rear pivot link30is pivotally coupled to a rear lift link32at pivot point34. The rear lift link32has a generally triangular shape, as shown. Rearwardly and below pivot point34(as viewed inFIGS. 2 and 3), rear lift link32is pivotally coupled to a rear back pivot link36at pivot point38. The rear back pivot link36extends upward and is pivotally coupled at its opposite end to a back bracket40at pivot point42. The back bracket40is shaped as shown, with an upper extending leg that is used to couple the back bracket40to a back of the recliner. The forward, lower area of the back bracket40is pivotally coupled to an upper end of a forward back pivot link44at pivot point46. The lower end of forward back pivot link44is pivotally coupled to a seat mounting plate48at pivot point50(as viewed inFIG. 3). The rear lift link32is also coupled to the seat mounting plate48at pivot point52, which is below pivot point50. As best seen inFIG. 2, a rearward end of a control link54is pivotally coupled to the rear back pivot link36at intermediate pivot point56. The forward end of the control link54is pivotally coupled to the seat mounting plate48at pivot point58, which is rearward of pivot point50(as viewed inFIG. 3).

Returning toFIG. 1, the front pivot link28extends upward from the base rail12. The upper end of the front pivot link28is pivotally coupled to a front lift link60at pivot point62. Rearwardly of pivot point62, the front lift link60is pivotally coupled to the seat mounting plate48at pivot point64. A connector link66is pivotally coupled on one end to the rear lift link32at pivot point68. The connector link66is pivotally coupled on the other end to the front lift link60at intermediate pivot point70(as viewed inFIG. 3).

Referring toFIG. 3, a bell crank72is pivotally coupled to the seat mounting plate48at pivot point74. The bell crank72is shaped as shown, having pivot point74at an intermediate position between a first end and a second end. The first end of the bell crank72extends upwardly from pivot point74and is pivotally coupled to a rear end of a crank connector link76at pivot point78. A front end of the crank connector link76is pivotally coupled to the front pivot link28at intermediate pivot point80. The second end of the bell crank72extends downwardly from pivot point74and is pivotally coupled to a footrest drive link82at pivot point84. The footrest drive link82extends from the connection to the bell crank72forwardly and is pivotally coupled on its forward end to a rear ottoman link86at intermediate pivot point88. The rear ottoman link86is pivotally coupled on its rear, upper end to the seat mounting plate48at pivot point90. The opposite end of the rear ottoman link86is pivotally coupled to a main ottoman link92at pivot point94. In the fully reclined position, the main ottoman link92extends upwardly and forwardly from the rear ottoman link86. The upward, forward end of the main ottoman link92is pivotally coupled to an ottoman bracket96at pivot point98. Additionally, the main ottoman link92is pivotally coupled, at an intermediate point, to a front ottoman link100at pivot point102. The front ottoman link100is pivotally coupled on one end to the seat mounting plate48at pivot point104, and is pivotally coupled on the other end to a shielded ottoman link106at pivot point108. The shielded ottoman link106is pivotally coupled on its other end to the ottoman bracket96at pivot point110. An intermediate point of the shielded ottoman link106is pivotally and slidably coupled to a mid-ottoman bracket112at slidable pivot point114. A mid-point of the mid-ottoman bracket112is pivotally coupled, at an intermediate point, to the main ottoman link92at pivot point116.

The recline mechanism described above can be implemented as a motorized or manual version, depending on the desired end use. As a manual version, a drive tube (not shown) is pivotally coupled to the seat mounting plate48at pivot point118(as viewed inFIG. 1). The drive tube is controlled by a lock mechanism. The lock mechanism includes a lock bracket120and a lock link122, best seen inFIG. 2. The lock bracket120is coupled on one end to the drive tube and configured to operatively lock the recline mechanism in the closed position (shown inFIGS. 1 and 2). The other end of the lock bracket120is pivotally coupled to a rear end of the lock link122at pivot point124. The front end of the lock link122is pivotally coupled, generally at a mid-point, to the rear ottoman link86at pivot point126.

Referring toFIG. 4, as a motorized version, a motor tube128is secured to and between the footrest drive links82. More specifically, a motor tube bracket130is fixedly secured to the footrest drive link82at coupling point132. The opposite end of the motor tube bracket130is fixedly coupled to the motor tube128, such as by welding. A clevis134is fixedly coupled to the motor tube128midway along the motor tube128, facilitating a pivotal coupling to one end of a motor driven trolley136. The trolley136rides along a track138. The track138is supported on a front end by the trolley136and on the opposite end by one of the cross members14to which the track138is fixedly coupled. A motor140drives the trolley136along the track138and holds the trolley136at positions associated with the recline mechanism being in at least the closed position, the TV position, and the fully reclined position.

Turning now toFIGS. 5 and 6, section views of alternative pivotal connections between the front pivot link28and the base rail12at pivot point190is depicted. In some embodiments of the recline mechanism, a stop member200is coupled to the base rail12as viewed inFIG. 5. The stop member200may comprise a pin, in accordance with some aspects. In other aspects, the stop member200may comprise a bushing. When the recline mechanism is in the closed position, the front pivot link28contacts the stop member200and the front pivot link28, and thus the recline mechanism is prevented from moving in the rearward direction passed the closed position. In some aspects, the front pivot link28may include a mating stop surface202. The stop member200may contact the mating stop surface202when the recline mechanism is in the closed position. The mating stop surface202may be integrally formed on the front pivot link28. In another embodiment of the recline mechanism shown inFIG. 6, the stop member200may be coupled to the front pivot link28. In such embodiments, the stop member200contacts the base rail12when the recline mechanism is in the closed position preventing the front pivot link28and therefore the recline mechanism from moving in the rearward direction passed the closed position. Further, in such embodiments, the mating stop surface202may be formed on the base rail12.

In still other embodiments, the linkage mechanism26includes one or more additional stop members that work in cooperation to hold the recline mechanism in the closed position. For example, the exemplary linkage mechanism illustrated inFIGS. 1-3includes a second stop member204(as viewed inFIG. 2), a third stop member208(as viewed inFIG. 1), and a fourth stop member212(as viewed inFIG. 2). The second stop member204is coupled to the rear lift link32and is configured to contact the seat mounting plate48when the recline mechanism is in the closed position. In some aspects, a second mating stop surface206(as viewed inFIG. 2) may be formed on the seat mounting plate48. The second stop member204may contact the second mating stop surface206when the recline mechanism is in the closed position. The third stop member208is coupled to a middle portion of the bell crank72and is configured to contact the connector link66when the recline mechanism is in the closed position. In some aspects, a third mating stop surface210(as viewed inFIG. 1) may be formed on the connector link66. The third stop member208may contact the third mating stop surface210when the recline mechanism is in the closed position. The fourth stop member212is coupled to the front lift link60and is configured to contact the seat mounting plate48when the recline mechanism is in the closed position. In some aspects, a fourth mating stop surface214(as viewed inFIG. 2) may be formed on the seat mounting plate48. The fourth stop member212may contact the fourth mating stop surface214when the recline mechanism is in the closed position, which prevents the front lift link60from rotating forwardly. In other aspects, a fifth mating stop surface216(as viewed inFIG. 2) may be formed on the rear ottoman link86. The fourth stop member212may contact the fifth mating stop surface216when the recline mechanism is in the closed position, which prevents the front lift link60from rotating rearwardly. Although not illustrated in the figures, the fifth mating stop surface may alternatively be formed on the footrest drive link82rather than on the rear ottoman link86.

In operation, when a user sits in the recliner when the recline mechanism is in the closed position a load is applied to the recliner. If there is slack in the recline mechanism, the seat of the recliner may move when carrying the user's load. The seat of the recliner cannot move, however, when the front pivot link28cannot move. The front pivot link28cannot move when the stop member200is used. Hence, the stop member200reduces or eliminates slack in the recline mechanism and reduces or eliminates slack in the seat of the recliner. That is, the stop member200controls front to rear movement of the front pivot link28and therefore the rear pivot link30when the recline mechanism is in the closed position.

In the exemplary linkage mechanism illustrated inFIGS. 1-3, the second stop member204controls the forward rotation of the rear lift link32and the chair back. The third stop member208controls the rearward rotation of the rear lift link32and the chair back. The fourth stop member212controls the rearward rotation of the front lift link60, the rear lift link32, and the chair back and also prevents up and down movement of the seat in a direction normal to the surface the chair is supported upon.

The exemplary arrangement of the above described stop members200,204,208, and212provide a more positive way of preventing movement (i.e., slack) of the recline mechanism, and more particularly, the links of the linkage mechanism when in the closed position. This exemplary arrangement provides this improved way of preventing movement without adding excess loading of the rivet joints to prevent the movement. Excess loading of the rivet joints increases the force required to close the recline mechanism, which is a problem from which prior methods have suffered.