Abstract:
A hinge and bracket system for a cushion seat back is provided. A bracket is attached to the side of a cushion seat back which is laying flat. The bracket is connected to a rotatable shaft, which in turn is connected to a toothed gear and a pawl. When the cushion seat back is raised upward, the toothed gear and an element of the pawl allow the cushion seat back to ratchet upwards, with the capability to lock the cushion seat back at any tooth. When the cushion seat back is raised above about 90 degrees, the pawl is forced to disengage from the toothed gear and the cushion seat back is unlocked and can be placed back in the original flat position. This hinge and bracket system may be employed in marine operations, especially for water skiing.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part application of co-pending U.S. patent application Ser. No. 14/138,435 filed Dec. 23, 2013, entitled A Hinge Employing A Ratchet For An Upholstery Seat, which claims the benefit of U.S. Provisional Application No. 61/740,615 filed on Dec. 21, 2012, entitled Ratchets for Upholstery Seat, the disclosures of the prior applications are incorporated by reference, in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention is directed to a hinge which includes a ratchet and pawl to permit an element of upholstery to move from a flat zero degree position upwardly to about a 90 to 100 degree position. The element of upholstery being discussed is a cushion that folds up to form a back rest which is provided on the stern of a recreational watercraft. Current designs do not allow for easy adjustment of seat and cushion positions for usage in sunbathing, installing water-ski hardware, rear deck lounging. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed to a ratchet mechanism and bracket to be affixed to a cushion seat back on the rear deck of a marine craft, to permit the cushion seat back to be adjusted into one of any of a plurality of positions for the comfort of the user. Although the instant ratchet mechanism is employed in a marine application, it is not limited solely to such an application. The instant structure may be used on any of a plurality of chaise lounge type recliners as well as any other related devices, recliners or seat backs, deck cushions on cruisers, interior lounge seats, and armrests. The disclosed invention is an improved hinge system that can work on or be mounted to any structure that is needed to adjust to various positions. Such structures without limitation could be for a hatch lid for a storage compartment, grill lids, any hinged devices, or for an engine rooms. 
     A toothed gear with a central aperture and a surrounding circular element has a plurality of teeth protruding radially outwardly along the circumference. A shaft is connected to a bracket and is secured in the central aperture of the toothed gear by a locking key. When the toothed gear rotates, the shaft rotates, moving the bracket and thus moving the cushion seat back. A specialized rotatable pawl has a first toothed portion for interacting with the gear teeth, a central pawl tongue located above the first tooth portion, and a second portion which is toothless. Depending on the rotation of the toothed gear, the pawl may lock the cushion seat back in an upright position, or allow the cushion seat back to move freely back to an initial position. 
     The current invention has a main gear with a plurality of ratchet teeth approximately every seven (7) degrees, which permits the cushion to be locked into a position seven (7) degrees apart from a previous position. Different embodiments of the ratchets for the upholstery seat can change this seven (7) degree separation by changing the number of teeth to be a greater number of a lesser number. The instant ratchet pawl system allows the upholstery which is affixed to the brackets and the spring ratchet pawls system to move upwardly from the deck with the ratchet engaged, moving 7 degrees for each tooth moved forward on the gear teeth until it reaches approximately 97 degrees. 
     At this point the release spring deactivates the ratchet system allowing the upholstery to return to the stern deck, where the spring activates the ratchet system again to allow the upholstery to be ratcheted back up to 97 degrees. 
     The invention is employed on the port and starboard side of the upholstery chair which permits the upholstery chair to move from a flat position to a locked position. A bracket portion proximal the hinge is secured to the deck to where it retains a fixed upholstery pad secured to the deck. 
     All of the elements of the invention are made of metal. Stainless steel, while expensive, may have a greater longevity, especially in salt water. In embodiments of the invention which are intended to be used on the land, other metals or even synthetic polymers may be employed. 
     Although the invention is illustrated and described herein as embodied as a hinge assembly for an upholstery seat, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. 
     The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded view of the pawl and ratchet spring hinge element of the invention in relation to the multiple brackets. 
         FIG. 2  is a view of the pawl and ratchet spring hinge element of the invention with the brackets shown in such a position so that if the movable upholstery were shown, it would be lying flat against the stern deck. 
         FIG. 3  is a view of the pawl and ratchet spring hinge element of the invention with brackets shown in such a position that if the movable upholstery were shown, it would be at about halfway between it&#39;s resting (zero degree) position and it&#39;s maximum approximate 97 degree position. 
         FIG. 4  is a view of the pawl and ratchet spring hinge element of the invention with the brackets shown in such a position that if the movable upholstery were shown, it would be at it&#39;s maximum elevation (approximately 97 degrees) with respect to the stern deck. 
         FIG. 5  is a perspective view of movable upholstery secured by the spring hinge elements of the invention at an approximate level as that shown in  FIG. 3 . 
         FIG. 6  is an exploded perspective view of another embodiment of the hinge including the ratchet mechanism. 
         FIG. 7  is a side view showing the main gear moving in a ratcheting direction approaching the release position of the pawl. 
         FIG. 8  is a side view showing the pawl being disengaged by the stop pin. 
         FIG. 9  is a side view showing the main gear moving in a direction away from the stop pin which engage the pawl with the main gear  14 . 
         FIG. 10  is a side view showing an inside of the cover holding the spring in position. 
         FIG. 11  is a perspective view of movable upholstery secured by the spring hinge elements of the invention 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , an exploded view of the hinge employing a ratchet mechanism  5  for a movable upholstery seat or seat back  76  (best seen in  FIG. 5 ) is shown. From right to left, a cover  10  is secured to the fixed mount bracket  30 . Proximal the interior side of the cover  10  is the pawl  12 , the pawl  12  has a first side  60  with teeth  52  and a second side  56  with no teeth as well as a pawl tongue  54  the circular element/main gear  14  has a plurality of teeth  50  radially disposed about a circumferential edge thereof. The ratchet mechanism  5  includes a ratchet spring hinge element  64 , a first brass bearing  18 , a first set screw  20 , a second set screw  22 , a snap ring  24 , a shaft key  26 , and a second brass bearing  28 . The washer (preferably Delrin® a registered trademark of E.I. Dupont De Nemours and Company, Wilmington, Del.)  36  has a central circular opening  36 A. This is immediately adjacent the central circular opening  30 A of fixed mount bracket  30 . Fixed mount bracket  30  includes a pair of bolt holes  32 . The second brass bearing  28  has a central circular opening  28 A immediately adjacent the central circular opening  36 A. Intermediate the second brass bearing circular opening  28 A is the snap ring  24  with a central circular opening  24 A. The snap ring  24  with a central circular opening  24 A is adjacent to the first brass bearing  18  which has a circular opening (not shown). Shaft  48  inter fits down the cavity formed by the washer central circular opening  36 A, the fixed mount bracket circular opening  30 A, the second brass bearing central circular opening  28 A, and through the snap ring central circular opening  24 A and into the main gear central circular opening  14 A. A key way  26 A is formed parallel to the shaft  48  on the side of the central circular opening  14 A. The shaft key  26  fits into the key way  26   a  securing the shaft to the main gear  14 , and thus when the main gear  14  is caused to rotate with the pawl teeth  52  engaged to the gear teeth  50  of the main gear  14 , the cushion support plate  44  rotates therewith. Perpendicular to the cushion support plate  44  is the backrest support  40 , which includes a plurality of apertures  42  to secure an upholstery back portion or seat back  76  thereto. Main gear  14  has an annular shoulder  14 B. The movement of the pawl teeth  52  against the gear teeth  50  allows the cushion support plate  44  to move in seven degree increments. This has the effect of rotating the upholstery back portion or seat back  76  at the same angular distance.  FIG. 2  is a view of the pawl tongue  54 , and ratchet spring hinge element  64  of the invention with the brackets shown in such a position so that if the movable upholstery  76  (see  FIG. 5 ) were shown, it would be lying adjacent the rear of the movable cushion support plate  44  and lying flat against or in close proximity to the stern deck  80 . In  FIG. 2 , the upholstery adjacent element  44 A, would be at a zero angle with respect to the stern deck  80 . The ratchet spring hinge element  64  is shown secured about a third set screw  22 A with the ratchet spring hinge element extension  64 A intermediate the set screw  20  and the pawl tongue  54 . Spring extension  64 A can rest against annular shoulder  14 B. In this position, the pawl teeth  52  are shown inter-meshed with a portion of the gear teeth  50  of the main gear  14 . A plurality of apertures  90  are located through the main gear  14  at approximately thirty degree intervals. The plurality of apertures  90  are located intermediate the gear teeth  50  and the main gear central circular opening  14 A. The apertures  90  are designed to receive set screws or other devices therein in a different configuration than the first set screw  20  and the second set screw  22  as shown and located in  FIGS. 2-4 . This permits different angular displacement of the shaft  48 , with the consequent different angular displacement of the upholstery attached to movable cushion support plate  44 . The apertures  90  may also receive start-stop pins  72  in desired apertures  90  instead of the first set screw  20  and the second set screw  22 , which pins  72  serve the same purpose as the set screws. 
       FIG. 3  is a view of the pawl tongue  54 , pawl  12  and ratchet spring hinge element  64  of the invention with the cushion support plate  44  shown in such a position that if the movable upholstery were shown, it would be at about halfway between its resting (zero degree) position and its maximum 97 degree position. Since the upholstery is still moving upward, the pawl teeth  52  are still shown inter-meshed with a portion of the gear teeth  50  of the main gear  14 . 
       FIG. 3  shows the ratchet spring hinge element  64  in a locked position  66  thereof. Further, the pawl teeth  52  are shown in their locked position  68 . This keeps the backrest in a mid-locked position as shown. The main locking gear  14  is shown interfacing with the pawl  12 . The configuration of the following components change as the seat back  76  is moved up and down. The components include the main gear  14 , pawl  12 , the ratchet spring hinge element  64  and the ratchet spring hinge element extension  64 A orientation. This occurs when the upholstery  76  (see  FIG. 5 ) secured to the cushion support plate  44  is moved to approximately the (42-49) degree position. This is due to the fact that the pawl teeth  52  have permitted the main gear  14  to rotate in 7 degree increments, causing the shaft  48  to rotate approximately 42-49 degrees and move the support plate  44 . In this position, the pawl teeth  52  are still shown inter-meshed with a portion of the gear teeth  50  of the main gear  14 . 
       FIG. 4  is a view of the pawl  12  and ratchet spring hinge element  64  of the invention with the brackets shown in such a position that if the movable upholstery were shown, it would be at its maximum elevation (approximately 97 degrees) with respect to the stern deck. It is at this point where the rotation of the main gear  14  disengages the pawl teeth  52  by rotating the pawl tongue to the left after hitting the second set screw  22 . At this point the second pawl side  56  with no teeth is pushed closest to the gear teeth  50  which permits the main gear  14  and shaft  48  to rotate counterclockwise back to the zero angle position which is shown in  FIG. 2 . The movement of the pawl tongue  54  by the first set screw  20  and the second set screw  22  respectively allows engagement of the pawl teeth  52  with the gear teeth  50  and the subsequent disengagement of the pawl teeth  52  from the gear teeth  50 . Disengagement of the pawl teeth  52  displaces the second pawl side  56  towards the gear teeth  50  which allows the pawl teeth  50  and subsequently the shaft  48  for the seat back  76  to rotate freely from the upright position of the seat back  76  and bracket  44  shown in  FIG. 4 . to the original position of the seat back  76  and bracket  44  in  FIG. 2 .  FIG. 4  shows the ratchet spring hinge element  64  in a released position. Further, the pawl teeth  52  are shown in a release position  68   a . At this point, the pawl teeth  52  are displaced by the pawl tongue  54  via the first set screw  20  to re-engage the gear teeth  50  of the main gear  14  and allow the upholstery seat  76  to move upward again at an approximate seven degree increment as the pawl teeth  52  ratchet the gear teeth  50 . This allows the backrest to be secured into a comfortable position. 
       FIG. 5  shows the upholstery seat back  76  being supported in an upright position by a first hinge  10 A, including ratchet mechanism  5  and bracket  30  and a second hinge  10 , including further ratchet mechanism  5  and bracket  30 . Cover element  10  as shown in  FIG. 1  encloses the pawl  12 , the pawl tongue  54  the main gear  14 , and all other interior mechanisms. A portion of fixed mount bracket  30  is shown with the bend  46  in the cushion support plate  44 . The bend  46  in the cushion support plate  44  moves the cushion support plate  44  outwardly from the fixed mount bracket  30  (best seen in  FIG. 1 ) to permit motion of the cushion support plate  44 . In  FIG. 5  the cushion or movable upholstery  76  is shown in a position which would be actualized by the view of the hinge, ratchets, and brackets shown in  FIG. 2 . Four apertures  38  (of which only two are shown in  FIG. 1 ) are located on the fixed mount bracket  30  are employed with mechanical fasteners to fix the entire assembly to a deck. 
       FIG. 5  also shows fixed cushion  78  which can be attached to the deck proximal the rear of the boat. Arrow  85  shows the orientation of the movable cushion  76  and fixed cushion  78  with respect to the front of the boat or other craft. 
       FIG. 6  shows another embodiment in which the spring action for holding the pawl  12  in the correct positions is achieved with a variation of the spring  164  and the disposition thereof. The embodiment of  FIG. 6  also combines elements in order to eliminate some components and make the assembly easier to produce. Also, the cushion support plate  44  has been flipped so that the cushion support  40  faces the hinge and the bend  46  of the first embodiment is removed. The configuration of the elements is further shown in  FIG. 11 , which shows the cover  10  facing the fixed cushion  78 , which is opposite  FIG. 5 . 
       FIG. 6  shows that the mount bracket  30  receives the main gear  14  with the second brass bearing  28  disposed therebetween. In  FIG. 6 , the main gear  14  is of one piece construction, which eliminates the requirements for the shaft key  26  and the snap ring  24 . The pawl  12  is held at the mount bracket  30  by the first brass bearing  18 . The pawl  12  includes the first side  60  and the second side  56  with respect to the tongue  54 , when viewing the pawl  12  along an axis of rotation of the pawl  12 . The main gear  14  includes activation pins  200 , which are disposed in apertures  90 . If adjustability of the range of motion of the seat back  76  is not a concern, the activation pins  200  may be formed as part of the main gear  14  in order to increase the cross sectional area thereof and increase the strength of the activation pins  200 . In other words, the activation pins would not have to be round and could have an arc-shaped cross-section. The activation pins  200  establish the range of motion of the seat back  76  by controlling engagement of the pawl  12  with the main gear  14 . While the elements  200  are designated as pins, it is certainly possible for the activation pins  200  to be provided as set screws as is the case in the embodiment shown in  FIG. 1 . The tongue  54  can be any type of actuating projection or surface on the pawl  12  that is able to engage the activation pins to move the pawl  12 . 
     A brass bushing  80  having female threads guides the main gear  14  on a cover side of the main gear  14 . The bushing  80  receives a screw  7 , which holds the bushing  80  to the cover  10 . 
     As seen in  FIG. 10 , the cover  10  defines ledges  10   b , which hold the spring element  164  in a proper position to interact with the pawl  12  and allow for the ratcheting of the pawl teeth  52  in the teeth  50  of the main gear  14 . The spring element also holds the pawl  12  in a free-wheeling position once the teeth  52  have been disengaged from the teeth  50  of the main gear  14  and the second side  56  being moved adjacent said main gear  14  due to interaction of the pawl tongue  54  with the appropriate stop pin  200 . The spring  164  in the embodiment of  FIG. 6  is provided as a strip. The ledges  10   b  support the spring  164  at opposite ends thereof and allow deflection of the spring  164  at a bend  164   a  between the opposite ends of the spring  164 , where the spring  164  interacts with the pawl  12 . The cover  10  also includes a blind hole  10   c  at the axis of rotation  12   a  which supports the pawl  12  on the cover side of the pawl  12 .  FIG. 6  shows screws  7  which fasten the mount bracket  30  to the cover  10 . It noted the cover is removed from  FIGS. 7-9  and therefore, the ledges which support the spring  164  are not seen in  FIGS. 7-9 . Although the ledges  10   b  are shown as part of the cover  10 , it is possible for the ledges  10   b  to be provided on the mount bracket  30 . 
     The operation of the ratchet mechanism  5  will be discussed with respect to  FIGS. 7 ,  8 , and  9 . The activation pins  200  serve to control the location of the pawl  12  (ratcheting/free-wheeling) by interaction with the pawl  12 , particularly, the pawl tongue  54 . Although the embodiment of  FIG. 6  has different structure with respect to the spring element  164 , the description of the operation of  FIG. 6  also generally applies to the embodiment of  FIG. 1  in the manner which the spring allows the pawl  12  to be positioned.  FIGS. 7-9  show that the pawl  12  is disposed in a position between the activation pins  200 . 
       FIG. 7  shows the seat back  76  moving in the ratcheting direction (clockwise in  FIG. 7 ) towards the adjacent activation pin  200  with the pawl teeth  52  and the main gear teeth  50  in engagement. As the seat back  76  is raised and the pawl ratcheted, the spring  164  deflects and allows the pawl  12  to pivot to let the teeth  50  and  52  pass over one another to the next ratchet position. As the movement continues, the pawl tongue  54  comes into contact with the activation pin  200  and causes the pawl teeth  52  to disengage from the main gear teeth  50 . The pawl  12  is rotated by the activation pin  200  until the pawl  12  is held by the spring  164  in a release position released from the main gear  14 . The release position is where the second side  56  is moved toward the main gear  14  and since no teeth are present on the second side  56  and clearance is present between the pawl  12  and the main gear  14 , the main gear  14  is able to free-wheel. In the embodiment of  FIG. 6 , the pawl  12  is held in the release position at the bend  164   a  of the spring  164 , which is shown in  FIG. 8 . It is at this point that the main gear  14  can free-wheel to put the seat back in a flat position. At the flat position, the other activation pin  200  contacts the pawl tongue  54  and rotates the pawl  12  so that the pawl teeth  52  once again engage the main gear teeth  50 .  FIG. 9  represent a point just after the pawl teeth  52  and the main gear teeth  50  are re-engaged and the seat back  76  is being moved is a raising direction and the spring  164  holds the pawl  12  in a position where the pawl teeth  52  are able to ratchet in the main gear teeth  50 . 
     The present invention is a hinge system, for a cushion seat back on a boat which may be used for water skiing, having a shaft with a first end and a second end, where the shaft first end is connected to a bracket, where the bracket is affixed to a cushion seat back, and the cushion seat back is initially in a flat position at the rear of the boat. The shaft second end is secured by a locking key in a central aperture of a main gear, this main gear having a radius and a circumference, as well as a plurality of teeth equally distributed radially outward about the circumference of the main gear. 
     A plurality of apertures pass through the main gear, these plurality of apertures are equidistant from one another, and the plurality of apertures are intermediate the central radius of the main gear and the plurality of teeth which radially surround the circumference of the main gear. 
     The hinge system of this invention further includes a pawl with a tongue, where the pawl is rotatably fixed proximal the plurality of teeth, which radially surround the circumference of the main gear. The pawl has a lower portion and an upper portion, and the lower portion has several teeth, while the upper portion has no teeth. 
     The hinge system of the invention further includes a first set screw and a second set screw, where the first set screw fixed in one of the plurality of apertures above upper portion of the pawl. The second set screw fixed in a second one of the plurality of apertures below lower portion of the pawl. The invention further includes a spring having a body and an elongated tail, where the spring body is fixed in the one of the plurality of apertures above and adjacent the first set screw, and the elongated tail traverses from the spring body to a position above and in contact with the second set screw. In this configuration, the several teeth of the lower portion of the pawl are inter-meshed with an equal number of the plurality of teeth of the main gear and when the cushion seat back is lifted up from an initial flat position, the shaft rotates the main gear, and several teeth of the pawl are displaced from the equal number of the plurality of teeth of the main gear to a second set of a plurality of teeth on the main gear which locks the seat back at a second position equal to the position where said cushion seat back was lifted. 
     Additionally, when the cushion seat back is lifted up from any position to a position above about 90 degrees, the spring rotates or urges the pawl tongue downward, disengaging the several teeth of the pawl which are inter-meshed with an equal number of the plurality of teeth of the main gear and thus moves the upper portion of the pawl to a position proximal the plurality of the teeth of the main gear, permitting the cushion seat back to be moved back to an initial flat position.