Abstract:
In preferred embodiments of the invention, rocker cams are positioned intermediate an upper plate assembly and a lower base with a plurality of biasing springs under tension extending between the upper plate assembly and the lower base. Spring retention means are incorporated into the lower base and upper plate assembly providing for direct attachment of the biasing springs thereto obviating the need for spring mechanisms and threaded fasteners for connecting the spring mechanism to the upper plate and lower base. The base comprising a lower support plate configured as a gusseted tray connects to a pair of floor contacting side rails. The upper plate assembly, also preferably configured as a gusseted tray, is fixed to the pair of rocker cams rockingly engaged on the side rails. Vertical flanges are provided on the sides of the upper plate assembly for attaching the reclining mechanism. Each of the upper and lower support plates, in preferred embodiments, are fabricated from plates having elongate edge tabs bent vertically forming strengthening portions. Additional elongate angled recesses are formed in the plates for further strengthening.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/493,630 entitled “Rocker Recliner Mechanism”, filed Aug. 7, 2003, hereby fully incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to rocker-recliner chairs and more specifically to mechanisms for rocker-recliner chairs.  
       BACKGROUND OF THE INVENTION  
       [0003]     Rocker-recliner chairs have been a popular home and commercial furniture item for many years. Myriad different rocker-recliner mechanism configurations for rocker-recliners have been developed over time. Examples of prior art rocker-recliner mechanisms, including recliner mechanisms, may be found in U.S. Pat. No. 4,423,903 to Gerth; U.S. Pat. No. 4,519,647 to Rogers; Re U.S. Pat. No. 33,704 to Rogers; U.S. Pat. No. 4,544,201 to Rogers; U.S. Pat. No. 4,707,025 to Rogers; U.S. Pat. No. 5,121,967 to Rogers; U.S. Pat. No. 5,171,000 to LaPointe et. al.; U.S. Pat. No. 5,876,094 to Hoffman; U.S. Pat. No. 6,000,754 to Lawson; and U.S. Pat. No. 6,061,891 to Hoffman; all of which are hereby fully incorporated herein by reference.  
         [0004]     Prior art rocker-recliner mechanisms typically include a base portion with a pair of floor contacting rails laterally spaced apart and positioned at each side of the chair. A rocker cam rests on each of these rails. A recliner mechanism including a plurality of interconnected pivoting links is connected with each of the rocker cams so as to be rockable in a fore and aft direction.  
         [0005]     The pair of recliner mechanisms may be connected together and located by one or more bracing members, or may be connected by the chair frame. The mechanisms are usually actuated with a lever-operated shaft that is operably coupled with each mechanism so as to actuate the mechanisms together. One or more spring assemblies may be connected between the base and the rocker cams so as to bias the chair into an upright position and to assist the rocking motion of the chair. A “rocker-blocker” mechanism is sometimes provided to prevent rocking of the chair when the chair is reclined from its fully upright position.  
         [0006]     In some of the prior art rocker-recliner mechanisms mentioned above, such as U.S. Pat. Nos. 4,519,647 and 4,707,025, the biasing springs are connected directly between the rocker cam and the floor contacting rails of the base, and the recliner mechanisms are connected with the chair frame with little if any additional bracing between the mechanisms. Such configurations may be relatively heavy and lack lateral and torsional rigidity, thereby causing the overall mechanism to “loosen-up” over time and eventually fail.  
         [0007]     Other prior art commercialized mechanisms, such as illustrated in U.S. Pat. No. 6,000,754, have a cross-tube assembly positioned over the base rails and connecting the rocker cams. The biasing spring assemblies are mounted between the cross tube assembly and the base and the recliner mechanisms are connected at each side of the cross tube assembly. Each of the two spring assemblies is comprised of at least four components, two springs, a top cap and a bottom cap. The cross tube assembly is typically fabricated from multiple pieces of square or round metal tubing that are welded together. This cross tube assembly arrangement may be relatively expensive to fabricate due to the need to position together, assemble and weld the multiple tubing pieces and other components. Each of the two spring assemblies must be attached intermediate the base and cross tube assembly using four screw-nut combinations.  
         [0008]     What is needed in the industry is a rocker-recliner mechanism having fewer components facilitating easy fabrication at reduced cost, while maintaining suitable strength.  
       SUMMARY OF THE INVENTION  
       [0009]     In preferred embodiments of the invention, rocker cams are positioned intermediate an upper plate assembly and a lower base with a plurality of biasing springs under tension extending between the upper plate assembly and the lower base. Spring retention means are incorporated into the lower base and upper plate assembly providing for direct attachment of the biasing springs thereto obviating the need for spring mechanisms and threaded fasteners for connecting the spring mechanism to the upper plate and lower base. The base comprising a lower support plate configured as a gusseted tray connects to a pair of floor contacting side rails. The upper plate assembly, also preferably configured as a gusseted tray, is fixed to the pair of rocker cams rockingly engaged on the side rails. Vertical flanges are provided on the sides of the upper plate assembly for attaching the reclining mechanism. Each of the upper and lower support plates, in preferred embodiments, are fabricated from plates having elongate edge tabs bent vertically forming strengthening portions. Additional elongate angled recesses are formed in the plates for further strengthening.  
         [0010]     A feature and advantage of the invention is that the rocker mechanism may be manufactured for lower cost with easier assembly and fewer components. An upper plate and lower plate may be principally fabricated in a punch press rather than welded.  
         [0011]     A further feature and advantage is that the springs are secured intermediate the upper plate assembly and the base without the use of threaded fasteners that present the problem of coming loose after usage.  
         [0012]     A further feature and advantage is that the welded portion of the upper plate assembly and lower base do not require the precision assembly for welding of prior art designs nor is as much stress put on the welded joints as in prior art designs.  
         [0013]     A further feature and advantage of the invention is that similar strength of conventional designs may be accomplished with less weight. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a side plan view of a rocker-recliner chair;  
         [0015]      FIG. 2  is a perspective view of a rocker mechanism according to the present invention;  
         [0016]      FIG. 3   a  is an exploded elevational view of one side of the rocker assembly;  
         [0017]      FIG. 3   b  is a top elevational view of the spring attachment to the upper support plate of the mechanism;  
         [0018]      FIG. 3   c  is a cross-sectional view through line  3   c - 3   c  of  FIG. 3   b ;  
         [0019]      FIG. 4  is a side plan view of the rocker mechanism depicted in  FIG. 2 ;  
         [0020]      FIG. 5  is a front plan view of the rocker mechanism depicted in  FIG. 2 ;  
         [0021]      FIG. 6  is a top plan view of the rocker mechanism depicted in  FIG. 2 ;  
         [0022]      FIG. 7  is a detail perspective view of spring attachment to the upper support plate of the mechanism;  
         [0023]      FIG. 8  is a top plan view of the upper support plate;  
         [0024]      FIG. 9  is a side plan view of the upper support plate;  
         [0025]      FIG. 10  is a side sectional view of line  10 - 10  of  FIG. 8 ;  
         [0026]      FIG. 11  is a side plan view of the flange attached to the rocker cam;  
         [0027]      FIG. 12  is a perspective view of the upper support plate depicted in  FIG. 8 ;  
         [0028]      FIG. 13  is a bottom perspective view of the lower support plate;  
         [0029]      FIG. 14  is a top plan view of the lower support plate depicted in  FIG. 13 ;  
         [0030]      FIG. 15  is a side plan view of the lower support plate depicted in  FIG. 13 ; and  
         [0031]      FIG. 16  is a side sectional view of portion  16 - 16  of  FIG. 14 . 
     
    
     DESCRIPTION OF THE INVENTION  
       [0032]     Referring to  FIGS. 1 and 2 , the invention includes a rocker-recliner chair  20  and, particularly, a rocker mechanism  22 . The rocker-recliner chair generally includes a rocker mechanism  22 , a recliner mechanism  24  and chair frame  26 . The chair frame comprises a seat  28 , a backrest  30 , sides  32 , armrests  34  and a footrest  36 . The seat  28 , backrest  30 , sides  32 , armrests  34  and footrest  36  are built within or on a wooden frame  26 . The rocker mechanism  22  comprises a base  38 , rocker cams  40 ,  42 , bias springs  44 ,  46 ,  48 ,  50  and an upper support plate assembly  52 . The recliner mechanism  24  will typically comprise flanges and brackets for attaching a chair frame and may include a lazy tong linkage for attaching a footrest. Various recliner mechanisms are known in the art, such as illustrated in U.S. Pat. Nos. 4,423,903 and 4,662,673. The recliner mechanism  22  is replicated on each side of the chair  20 ; there being a recliner mechanism  22  on the right side of the chair  20  and a recliner mechanism  22  on the left side of the chair  20 .  
         [0033]     The base  38  shown generally in  FIGS. 1, 2  and  4  comprises a pair of side rails  54 ,  56  that rest on the floor surface F and a lower support plate  58  configured as a gusseted tray. The side rails  54 ,  56  are preferably fabricated from square steel tubing. Feet  60  are attached to the ends of the side rails  54 ,  56  to provide a stabilizing surface and to protect the floor surface on which the base of the chair rests. The lower support plate  58  is preferably welded to the two side rails  54 ,  56  to form a unitary assembly. The lower support plate  58  can be formed by a punch press from stock plate or sheet metal.  
         [0034]     The rocker cams  40 ,  42  each have a curved bottom surface  62  that allows the rocker-recliner to rock forward and aft. As shown in  FIGS. 2, 4 , and  5 , the curved surface  62  of each rocker cam  40 ,  42  rocks on the upper surface  63  of the base  38 . A rocker cam  40 ,  42  is located on each side of the chair base  38 . Attached to the upper surface  43  of each rocker cam  40 ,  42  is an upwardly projecting flange portion  64  at the outer margin thereof. The upwardly projecting flange portion  64  is a component of the upper support plate assembly  52  and is preferably formed from a piece of plate stock bent at a right angle with a lower leg  66  or horizontal portion sandwiched between the rocker cam and the metal forming the upper support plate  68 . The recliner mechanism is affixed to the flange portions  64  on either side of the chair  20  by conventional fasteners. The horizontal portions  66  of the flange portions  64  are laterally connected to the upper surface of each rocker cam  40 ,  42 . The ends of the upper support plate  68 , which is part of the upper support plate assembly  52 , are welded to each flange portion  64  so the upper support plate  68  connects the two rocker cams  40 ,  42 . In addition, the upper support plate  68  is affixed by screws, bolts or the like, to the rocker cams  40 ,  42 . Generally, the rocker cams are preferably made of wood, but may also be formed of plastic and the like.  
         [0035]     As shown in  FIGS. 2-7 , the springs  44 ,  46 ,  48 ,  50  are under tension and extend between the lower support plate  58  and the upper support plate  68  and are each attached directly to the lower support plate  58  and the upper support plate  68  by way of attachment means preferrably integrally formed within the respective plates.  
         [0036]     The lower support plate  58 , as shown in  FIGS. 13, 14 , and  15 , has a substantially rectangular opening  70  cut out of the body of the plate. Each edge created by the opening  70  forms a downwardly projecting flange portion  72 ,  74 ,  76 ,  78 . Each end flange portion  74 ,  78  has two slots  80 ,  82  and  84 ,  86 , contained therein. The exterior perimeter of the lower support plate  58  also has raised lips configured as downwardly projecting flange portions  88 ,  90 ,  92 ,  94  along all four sides of the plate. “Raised” when used herein means projecting away from the planar surface of the plate which can either normally or obliquely and includes upwardly or downwardly depending on the orientation of the plate. Hence, the lower support plate is not formed of any tubular sections. The lower surface  96  of the lower support plate  58  has a total of four curved tabs  98 ,  100 ,  102 ,  104  contained therein. Two curved tabs are located at each end of the lower support plate  58 , proximate the end flange portions  74 ,  78 , on the lower surface  96  of the lower support plate  58 .  
         [0037]     The upper support plate  68 , as best shown in  FIGS. 2, 3   b ,  6 ,  8 , and  12 , has a substantially rectangular opening  106  cut out of the body of the plate. Each edge created by the opening  106  forms an upwardly projecting flange portion  108 ,  110 ,  112 ,  114 . Each end flange portion  108 ,  112  has two slots  116 ,  118 , and  120 ,  122  contained therein. The exterior perimeter of the upper support plate  68  also has upwardly projecting flange portions  124 ,  126 , along the length of the plate. The upper support plate, therefore, is not formed of any tubular sections. The upper surface  128  of the upper support plate  68  has a total of four curved tabs  130 ,  132 ,  134 ,  136  contained therein. Two curved tabs are located at each end of upper support plate  68 , proximate the flange portion  108 ,  112  on the upper surface  128  of the upper support plate  68 . Each end of the upper support plate  68  is welded to a flange portion  64 , whose horizontal portion  66  is affixed to the upper surface  43  of a rocker cam  40 ,  42 . Therefore, the upper support plate  68  connects the two rocker cams  40 ,  42 . In addition, screws, bolts or the like, secure the end surfaces of the upper support plate  68  to the upper surface  43  of rocker cams  40 ,  42 . The upper support plate assembly  52  comprises the upper support plate  68  and the flange portions  64  and including the horizontal portions  66  of the flange portions  64 . Note that the upper support plate and lower support plate, with their raised lips both at the periphery and at the central opening is configured as two channels  139 . 1 ,  139 . 2 ,  139 . 3 ,  139 . 4  extending from each respective left plate portion  139 . 6 ,  139 . 7  to the right plate portion  139 . 8 ,  139 . 9 .  
         [0038]     The two pairs of springs  44 ,  46  and  48 ,  50  as shown in  FIGS. 1-7  are tensioned in place, between the upper support plate  68  and lower support plate  58 . The springs  44 ,  46  and  48 ,  50  provide a biasing force to bias the rocker cams  40 ,  42  to an upright position. Each spring  44 ,  46 ,  48 ,  50  is attached at its upper end directly to the upper surface  128  of upper support plate  68 . Each spring  44 ,  46 ,  48 ,  50  is also attached at its lower end to the lower surface  96  of lower support plate  58  by integral attachment means in the respective plates.  
         [0039]     As shown in  FIG. 13 , the hole or opening  70  in the lower support plate  58  may be formed by die-cutting. Tabs  138 ,  140 ,  142 ,  144 , are cut into the longitudinal edges  146 ,  148  that form the length of opening  70  such that the tabs  138 ,  140 ,  142 ,  144  are located proximate the intersections of the longitudinal edges  146 ,  148  and lateral edges  150 ,  152 . The extension flaps  72 ,  76  created by the tab cut-outs along the longitudinal edges  146 ,  148  are bent downwards to form flanges  72 ,  76 . The extension flaps  74 ,  78  formed at the lateral edges  150 ,  152  are also bent downwards to form flanges  74 ,  78 . Two slots  80 ,  82 ,  84 ,  86  are cut into each of the lateral edge flanges  74 ,  78  thus formed. On the lower surface  96  of the lower support plate  58  proximate lateral edge flange  74  are formed two curved tabs  98 ,  100 . Two curved tabs  102 ,  104  are also formed on the lower surface  96  of the lower support plate  58  proximate lateral edge flange  78 . The exterior side flanges  88 ,  92  and end flanges  90 ,  94  of the lower support plate  58  may be formed by bending the margins of a flat plate downwards.  
         [0040]     Referring to  FIG. 12 , the hole or opening  106  in the upper support plate  68  may also be formed by die-cutting. Tabs  154 ,  156 ,  158 ,  160 , are cut into the longitudinal edges  162 ,  166  that form the length of opening  106  such that the tabs are located proximate the intersections of the longitudinal edges  162 ,  166  and lateral edges  164 ,  168 . The extension flaps  110 ,  114  created by the tab  154 ,  156 ,  158 ,  160  cut-outs along the longitudinal edges  162 ,  166  are bent upwards to form flanges  110 ,  114 . The extension flaps  108 ,  112  formed at the lateral edges  164 ,  168  are also bent upwards to form flanges  108 ,  112 . Two slots  116 ,  118 ,  120 ,  122  are cut into each of the lateral edge flanges  108 ,  112  thus formed. On the upper surface  128  of the upper support plate  68  proximate lateral edge flange  108  are formed two curved tabs  130 ,  132 . Two curved tabs  134 ,  136  are also formed on the upper surface  128  of the upper support plate  68  proximate lateral edge flange  112 . The exterior side flanges  124 ,  126  the length of the upper support plate  68  may be formed by bending the margins of a flat plate upwards.  
         [0041]     Referring to  FIGS. 12 and 13 , note that the upper support plate and lower support plate are configured substantially as trays with a lips  136 . 1  at their respective peripheries  136 . 2  and the centralized hole or opening that extends at least the majority of the width W and depth D of the plates.  
         [0042]     Referring specifically to  FIGS. 3   a ,  3   b ,  3   c , the two pairs of springs  44 ,  46  and  48 ,  50  that are fitted between the upper support plate  68  and the lower support plate  58  are affixed to the surfaces of the two support plates by way of the curved tabs  98 ,  100 ,  102 ,  104 , and  130 ,  132 ,  134 ,  136 . For example, the upper free end of spring  48  is placed through slot  120  until it positioned in place by punched out nubs  137 ,  137 . 1 . Tab  134  is bent over the end of the spring  48 . Curved tab  134 , the nubs  137 ,  137 . 1  and the slot  120  secures the spring  48  proximate the free end of the spring  48  to the upper surface  128  of the upper support plate  68  without separate fasteners. Likewise, the lower free end of spring  48  is placed, directly below, through slot  84  to curved tab  102 . Curved tab  102  then secures the spring  48  proximate the free end of the spring, and so affixes the spring  48  to the lower surface  96  of the lower support plate  58 . Weldments  137 . 4  secure the flange to the upper support plate. Screws  137 . 6  may secure the upper support plate and/or the flange to the rocker cam  42 .  
         [0043]     The other springs  40 ,  46 ,  50  are similarly affixed to the upper support plate  68  and the lower support plate  58 . It is understood that the springs  44 ,  46 ,  48 ,  50 , may be placed in any of the positions held by the springs between the upper support plate  68  and the lower support plate  58  and are attached to the upper support plate  68  and the lower support plate  58  through the positionally related slot and curved tab located above and below the spring. In other embodiments the springs may be in direct contact with upper and lower plate and be held in place with other attachment means such as clamp mechanisms utilizing screws or rivets. Alternatively they could be fixed with weldments.  
         [0044]     A recliner mechanism  24  attaches to the outer side of the flange portion  64  of each rocker cam  40 ,  42 . These recliner mechanisms  24  include flanges and brackets for attaching a chair frame  26  and a lazy tong linkage for attaching a footrest  36 . The recliner mechanisms  24  are connected by an actuating shaft and a brace. The recliner mechanism also may include a “rocker blocker” (not depicted) for preventing rocking motion of the chair when the chair is in a reclined position.  
         [0045]     The mechanism  22  of the present invention has important advantages over the prior art. The upper and lower support plates  68 ,  58 , may provide improved overall rigidity to the mechanism, in turn improving comfort and longevity of the chair. Further, the use of springs  44 ,  46 ,  48 ,  50 , that are directly attached to the upper support plate  68  and lower support plate  58  reduces the number of pieces making-up the rocker mechanism. Thus, the manufacturing process is simpler overall, and lower cost material may be used, leading to lower cost for the mechanism  22 .