Abstract:
A reclining mechanism for a furniture item includes support structure adapted for attachment to the furniture item, a footrest support bar connected for longitudinal movement with respect to the support structure between extended and retracted positions and actuating structure connected with the footrest support bar. The footrest support bar includes an S-shaped section and is connected to a footrest member for supporting the legs of the seat occupant. The actuating structure moves the footrest support bar along the S-shaped section between the extended and retracted positions to closely approximate a conventional footrest portion of a reclining mechanism, while presenting a simplified construction.

Description:
RELATIONSHIP TO OTHER APPLICATIONS 
     This patent application is a continuation-in-part application of U.S. patent application Ser. No. 09/298,334, filed Apr. 23, 1999, now U.S. Pat. No. 6,231,120, the disclosure of which is fully incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     This invention generally relates to reclining furniture and, more specifically, to a three-way reclining furniture item having a moveable seat, backrest and footrest. 
     BACKGROUND OF THE INVENTION 
     Conventional reclining furniture items, such as chairs, sofas and sectionals, generally have either two-way or three-way mechanisms for allowing the chair to be moved between upright and reclined positions. In a two-way mechanism, the seat is fixed to the backrest as a unitary structure so that the angle between the seat and backrest remains the same during reclining motion. If the piece of furniture has a three-way mechanism, the top of the backrest will angle downwardly and rearwardly relative to the seat as the furniture item moves from an intermediate reclined or so-called T.V. position to a fully reclined position. Likewise, the backrest will move or tilt back up as the furniture item moves from the fully reclined position to the T.V. position. Among the concerns with reclining mechanisms in general are complexity and cost issues. These mechanisms can comprise large numbers of linkages and pivots to give the desired movement to the furniture item. Understandably, the more linkages and pivot connections in a given reclining mechanism, the higher the cost of manufacture and assembly. It has also become conventional practice to design reclining mechanisms with “zero wall proximity” ability. This refers to the ability to place the item of furniture with the top of the backrest against or very close to a wall while still allowing movement of the furniture item into both intermediate and fully reclined positions without encountering interference from the wall. Generally, the addition of this feature to a mechanism has even further complicated the typical three-way reclining mechanism. Another problem associated with reclining mechanisms has been the noise that they produce in moving between the different chair positions. Again, this noise can be associated with the numerous moving linkages in the mechanisms. 
     There have been many attempts to incorporate rollers in reclining mechanisms in various ways to produce mechanisms allowing different movements. For example, see U.S. Pat. Nos. 3,874,724; 4,072,342; 4,364,603; 4,531,778; and 5,823,614. One area of improvement that would be desirable relates to the footrest linkage of the mechanism. Conventionally, a scissor linkage assembly has been incorporated to extend and retract the footrest. Consumers have become widely familiar and comfortable with the typical footrest movement between the retracted and extended positions. However, the linkage assemblies have high numbers of links and pivots and present exposed pinch points. Certain consumers may also find them unattractive when in the extended position. 
     Alternative designs have been proposed to simplify the typical footrest scissor linkage, however, none of these alternatives have been fully acceptable. For example, alternative footrest mechanism constructions are shown in U.S. Pat. Nos. 4,506,925 and 4,844,536. In general, the mechanisms shown in these patents substitute bars which carry a footrest between retracted and extended positions using linkages, rollers or both. One major drawback with previous proposals such as these is that the resulting movement of the footrest does not closely approximate the typical movement of a footrest as refined through years of reclining mechanism development. This is believed to be one reason that these alternative footrest constructions have not been accepted in the industry. 
     In view of various problems with reclining mechanisms, such as three-way reclining mechanisms, it would be desirable to simplify these mechanisms and make them more attractive by significantly reducing the number of linkages in the footrest support and actuation portion, while also reducing costs, noise and potential pinch points associated with the mechanisms. At the same time, it would advantageous to provide a mechanism which fully reclines in a smooth manner without significant effort by the seat occupant and without interfering with a closely adjacent wall located behind the backrest. 
     SUMMARY OF INVENTION 
     The present invention improves upon past reclining mechanisms by incorporating a simplified footrest support bar and actuating system that closely approximates the typical arc-shaped movement of an extending and retracting footrest mechanism. In the preferred embodiment, a reclining mechanism is provided for a furniture item to allow movement between upright and reclined positions. More specifically, this may include one upright position and two reclined positions, typically referred to as an intermediate reclined position or T.V. position and a fully reclined position. The reclining mechanism generally includes support structure adapted for attachment to the furniture item, and a footrest support bar connected for longitudinal movement with respect to the support structure between extended and retracted positions. In the preferred embodiment, the support structure includes a track and the footrest support bar is connected for movement along the track. At least one of the track and the footrest support bar includes an S-shaped section. A first end of the footrest support bar is adapted for connection to a footrest member for supporting the legs of a seat occupant. Actuating structure is provided and connected with the footrest support bar and operates to move the footrest support bar along the S-shaped section between the extended and retracted positions. 
     The actuating structure is operated by a drive mechanism located between the reclining mechanisms. The drive mechanism preferably includes a motor assembly operable to rotate a drive tube. The drive tube is operatively connected to the actuating structure. However, drive mechanisms other than a motor assembly are within the scope of the present invention. 
     In one advantageous and preferred configuration, the S-shaped section is on the footrest support bar. The S-shaped section of the footrest support bar functions to closely approximate the movement of a conventional footrest mechanism. Also, in furtherance of this advantage, the footrest support bar includes at least one roller attached for rotation thereto and the support structure further includes a track. The roller is mounted for movement along the track between the extended and retracted positions. In the preferred embodiment, the track includes at least one curved section between the first and second ends and, more preferably, the entire track curves upward and then downward from a rear portion to a front portion thereof. 
     While the support structure may take many forms, it preferably includes a seat supporting member mounted adjacent the footrest support bar in a manner allowing the actuating structure to travel along the track as the footrest support bar moves between the extended and retracted positions. The roller is attached proximate the second end of the footrest support bar and the track includes first and second stops, which may be the ends of the track, with the roller engaging the stops at the respective upright and reclined positions. In a three-way mechanism, the rollers will preferably engage the stops at the upright and intermediate reclined positions. The roller is connected for movement with the actuating structure along the track. At least one additional roller is connected to a front portion of the support structure adjacent the footrest support bar and engages the footrest support bar during movement between the extended and retracted positions. In the preferred embodiment, upper and lower rollers are connected to the front portion of the support structure. These upper and lower rollers will support and guide the footrest support bar during movement between the extended and retracted positions. Many other options, such as a zero wall proximity option, gliding option, swivel option, etc., may also be incorporated into a mechanism of the present invention. 
     The invention also generally contemplates a method of operating a footrest mechanism in a reclining furniture item as generally described above. The method involves maintaining the footrest in a generally vertical orientation, moving the footrest support bar simultaneously downward and outward, reorienting the footrest into an angled orientation, extending the footrest support bar through an upwardly and outward arc while the footrest moves through the angled orientation, and stopping the footrest support bar with the footrest in the generally horizontal orientation at an upper end of the arc and the footrest support bar extending between the seat and the footrest. The method further involves retracting the footrest support bar through an opposite downward and inward arc while the footrest moves through the angled orientation and moving the footrest support bar upward and inward toward the seat as the footrest approaches the seat. The footrest stops in the generally vertical orientation in a typical position tucked beneath the seat. 
     The invention further contemplates a reclining mechanism similar to the above-described mechanism but either alternatively or additionally including a footrest member that is connected for biased, pivotal motion with respect to the footrest actuating structure, such as the S-shaped footrest support bar. In one aspect, the footrest member is connected by at least one spring to the footrest actuating structure and the spring is mounted for movement into an over-center position for pivoting the footrest member into a leg supporting position upon extension thereof. In another aspect, the footrest member is pivotally connected to the footrest actuating structure in a pivoting fashion allowing pivoting motion in two directions whereby the front edge of the footrest member is pivotal downward in the leg supporting position and the rear edge of the footrest member is pivotal outward in the retracted position. This allows the footrest to float in a spring-biased fashion in concert with movement of the seat occupant&#39;s legs in the extended position. Also, as the footrest member is retracted against the furniture item, the rear edge of the footrest member, which becomes the upper edge in the retracted position, can pivot away from the furniture item in case of object, such as a person&#39;s body part, is caught between the footrest member and the remaining portions of the furniture item. 
     Additional features, objectives and advantages of the invention will be more readily appreciated from the description to follow, taken in conjunction with the accompanying drawings and the various configurations of the invention set forth in the appended claims. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a longitudinal cross sectional view of a schematically illustrated furniture item depicting a reclining mechanism constructed in accordance with the invention and shown from an inside perspective; 
     FIG. 1A is a perspective view of a portion of the reclining mechanism shown from an inside perspective with the drive assembly omitted for clarity; 
     FIG. 2 is another longitudinal cross sectional view of the reclining mechanism shown in FIG. 1, but illustrated in the intermediate reclined or T.V. position; 
     FIG. 3 is a partial cross sectional view similar to FIG. 2, but showing the mechanism in a fully reclined position; 
     FIG. 4 is an elevational view of the reclining mechanism taken from an outside perspective; 
     FIG. 5 is a partial elevational view similar to FIG. 4, but showing the mechanism in the intermediate reclined or T.V. position; 
     FIG. 6 is a partial elevational view similar to FIG. 5, but showing the reclining mechanism in a fully reclined position; 
     FIG. 7 is a fragmented top perspective view showing the drive mechanism of the present invention; 
     FIG. 8 is a fragmented top perspective view similar to FIG. 7, but showing the drive mechanism in a fully extended position; and 
     FIGS. 9A-9C are enlarged views of the footrest member showing the various positions and pivotal motions thereof. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to FIGS. 1-3, a reclining furniture item  10  constructed in accordance with the preferred embodiment includes a schematically illustrated backrest  12  and seat  14 . A footrest  16  is connected for extension and retraction in a manner to be described below. In this preferred embodiment, furniture item  10  is configured such that the backrest  12 , seat  14  and footrest  16  move with respect to a base member  18  and by way of a reclining mechanism  20  between the fully upright position shown in FIG.  1  and respective intermediate reclined and fully reclined positions shown in FIGS. 2 and 3. It will be appreciated that many other mechanism configurations, including two-way and three-way mechanisms, may incorporate one or more features of this invention. It will also be understood that, as in the typical case, two reclining mechanisms will be used in a given item of furniture. These mechanisms will be mounted on opposite sides of seat  12  and will be mirror images of one another. Only a description of one mechanism  20  will be detailed herein with the understanding that another mirror image mechanism is connected on the opposite side of furniture item  10 . 
     Reclining mechanism  20  includes a seat link or plate  22  connected for movement with seat  14  and backrest linkage  24  connected for movement with backrest  12 . An S-shaped footrest support bar  26  has a front end portion  28 . An extension  30  is pivotally secured at  32  to the front end portion  28  of the footrest support bar  26 . The extension  30  is pivotally secured to a support bracket  34  affixed to footrest  16 . A second, opposite end of the S-shaped footrest support bar  26  includes a roller  36  connected for rotation therewith. See FIGS. 4-6. Roller  36  is contained on a track which is preferably configured as a slot  38  contained within seat link  22 . S-shaped footrest support bar  26  is further supported and guided at a front end of seat link  22  by upper and lower rollers  40 ,  42 . These rollers engage footrest support bar  26  as it moves between retracted and extended positions as explained further below. The diameter of the lower roller  42  is larger than the diameter of the upper roller  40  to reduce the number of revolutions of the lower roller  42  and hence reduce the noise created thereby. In one preferred embodiment, the diameter of the lower roller  42  is three inches; however it may be any diameter. 
     As best illustrated in FIGS. 7 and 8, a generally rectangular seat supporting structure  50  comprises a pair of side portions  51 , a rear portion  52  and a front portion  53 . A bracket  54  supporting a roller  55  is secured to the front portion  53  of the seat supporting tube structure  50 . 
     Referring to FIG. 1, backrest linkage  24  includes a link  56  rigidly secured by fasteners  57  to the side portion  51  of the seat supporting structure  50 . A pivoting backrest link  58  is rigidly affixed to backrest  12  by fasteners  59  and includes a pivot  60  at one end secured to link  56 . Another link  62  has one end pivotally secured to backrest link  56  at a pivot connection  64  and has an opposite, lower end connected with a link  66  at a pivot connection  68 . Link  66  is generally L-shaped and includes a pivot connection  70  with link  56 . A lower end of link  66  is connected with a further link  72  at a pivot connection  74 . Link  72  is pivotally secured at  104  to the base member  18 . 
     As best illustrated in FIG. 4, base member  18  comprises a horizontally oriented first portion  76  adapted to engage the floor or supporting surface and a vertically oriented second portion  78  extending upwardly from the first portion  76  of the base member  18 . Thus, the base member  18  has a generally L-shaped cross sectional configuration. Although one configuration of base member  18  is illustrated and described, other configurations may be utilized in accordance with the present invention. 
     Spaced front and rear slotted brackets  80 ,  82 , respectively, are secured to the vertically oriented second portion  78  of the base member  18 . The front bracket  80  has a front track or slot  84  and the rear bracket  82  has a rear track or slot  86  contained therein. 
     Also illustrated in FIG. 4, another link  94  is connected at its upper end at pivot connection  93  to an inside surface of seat plate  22 . The lower end of link  94  is pivotally secured to a base plate or link  88  at a pivot connection  90 . At its forward end, base plate or link  88  is pivotally secured at  92  to another link  95 . Link  95  is pivotally secured at pivot connection  96  to an inside surface of seat plate  22 . As best illustrated in FIGS. 1 and 7, a first cross bar  98  is secured to link  95  with fasteners  97 . The cross bar  98  extends transversely from one reclining mechanism  20  to the other reclining mechanism. A second cross bar  99  likewise extends transversely from one reclining mechanism  20  to the other. The second cross bar  99  is secured to base plate  88  with fasteners  101 . See FIG.  3 . 
     As best illustrated in FIG. 7, an L-shaped bracket  100  is secured to the link  72  on the inside thereof and to a rotatable cross tube  102 . The cross tube  102  extends between the links  72  of the reclining mechanisms  20 . 
     Forward and rearward movement of seat  14  with respect to base member  18  is provided by front and rear rollers  106 ,  108  riding in respective front and rear tracks or slots  84 ,  86  contained in front and rear brackets  80 ,  82  respectively. As will be discussed below, this movement takes place between the T.V. or intermediate reclined position and the fully reclined position. It will be appreciated that rear roller  108  also moves independently of front roller  106  when the reclining mechanism  20  goes from the fully upright or closed position (FIG. 1) to the T.V. or intermediate reclined position (FIG.  2 ). As best illustrated in FIG. 7, rear roller  108  is connected to base link  88 , while front roller  106  is connected to link  95 . 
     As illustrated in FIGS. 7 and 8, a drive tube or torque tube  110  extending between the reclining mechanisms  20  is connected to a drive assembly  112  located therebetween. As best illustrated in FIG. 1A, a piece of angle iron  111  is secured to the drive tube  110 . The drive assembly  112  is operated by a seat occupant and will be described in more detail below. It will be appreciated that actuation members or assemblies other than the drive assembly  112  illustrated and described may be utilized to rotate the drive tube  110 . In addition, it will be appreciated that the drive assembly  112  may be located at other locations other than between the reclining mechanisms  20 . 
     FIGS. 4-6 respectively illustrate the fully upright, intermediate reclined or T.V. and fully reclined positions of mechanism  20  from an outside or elevational view. This better illustrates the actuating structure  113  for extending the footrest  16 . Actuating structure  140  preferably comprises links  114 ,  118 ,  122  and  124  connected for movement upon rotation of drive tube  110 . Bell crank link  114  is affixed for rotation with drive tube  110  and drive tube  110  is connected with drive assembly  112 , as described below, which is activated by a seat occupant. Bell crank link  114  is connected by a pivot connection  116  to a connecting link  118 . Another pivot connection  120  joins connecting link  118  to a drive link  122 . Drive link  122  is secured to secondary drive link  124  at pivot connection  126 . Secondary drive link  124  is secured at its opposite end to S-shaped footrest support bar  26  through roller  36  at pivot connection  128 . 
     The other end of drive link  122  rotates about a pivot connection  130  to another link  132 . As illustrated in FIG. 1A, an upper end of link  132  is secured to one end of V-shaped link  136  at  134 . The other end of the V-shaped link  136  is secured to link  137  at pivot connection  135 . The apex of V-shaped link  136  is secured at  139  to the seat plate/link  22 . The opposite end of link  137  is secured at pivot connection  133  to the inside surface of link  94 . 
     Referring back to FIGS. 4-6, an extension spring  138  is connected between a stud  140  extending outwardly from connecting link  118  and another stud  142  extending outwardly from drive link  122 . 
     During movement from the fully upright position shown in FIG. 1 to the T.V. position shown in FIG. 2, rotation of the drive tube  110  causes rotation of the bell crank link  114  located outside of the seat link/plate  22  in the direction of arrow  144  (see FIG.  4 ). Rotation of the bell crank link  114  causes the connecting link  118  to pull forwardly. The forward motion of the connecting link  118  causes the drive link  122  to rotate about a horizontal axis at pivot connection  130 . Spring  138  helps pull the drive link  122  forwardly. As the drive link  122  moves forwardly, the secondary drive link  124  pulls forwardly as well, causing the S-shaped footrest support bar  26  to move forwardly. 
     During movement from the fully upright position shown in FIG. 1 to the T.V. position shown in FIG. 2, the drive link  122  rotates until it abuts a stop  146  which extends outwardly from the seat link or plate  22 . As shown in FIG. 5, the stop  146  stops the rotation of the drive link  122 . 
     FIGS. 7 and 8 illustrate the drive assembly  112  referred to above. The drive assembly  112  is located between the two opposed reclining mechanisms  20 . The preferred embodiment of drive assembly  112  is a motor assembly  150 . While many different motor assemblies may be used, one which has proven satisfactory is model 9.25.000.080.30 manufactured by OKIN, Antriebstechnik GmbH &amp; Co. in Gummersbach, Germany. 
     The motor assembly  150  is pivotally secured at  152  to cross tube  102  by brackets  154 . The motor assembly  150  comprises a motor  152 , a drive housing  156  extending forwardly from the motor  152  and a movable housing  158  which travels the length of the drive housing  156 . A pair of spaced L-shaped brackets  160  are secured to the sides  162  of the housing  158  and to the drive tube  110 . 
     Upon activation of the motor  152 , a threaded drive shaft inside drive housing  156  rotates, causing the housing  158  which has a threaded nut or block (not shown) therein to travel forwardly along the drive housing  156 . The forward motion of the housing  158  causes the L-shaped brackets to rotate the drive tube  110  in the direction of arrow  164  (see FIG.  7 ). FIG. 7 illustrates the drive assembly  112  when the reclining mechanisms  20  are in the closed and tv positions, the tv position being illustrated in phantom. FIG. 8 illustrates the drive assembly  112  when the reclining mechanisms  20  are in the fully reclined position. 
     FIGS. 9A-9C illustrate the mounting and various possible movements of footrest  16  at the end of footrest support bar  26 . Bracket  34  has a generally planar first portion  43  secured to the underside of footrest  16  and a generally planar second portion  46  extending downwardly therefrom. A spring  44  is connected to the first portion  43  of bracket  34  and further connected to a stud  48  extending from the end portion  28  of footrest support bar  26 . Spring  44  is disposed above pivot  32  between bracket  34  and support bar  26  in essentially an on-center position when footrest  16  is in a retracted position. Spring  44  moves to an over-center position under the weight of a seat occupant&#39;s legs as footrest  16  moves to the extended position as shown in FIGS. 2 and 9C. Once in this position, footrest  16  can float in accordance with leg movement of the seat occupant in a manner described below. 
     Footrest  16  is mounted on a support bracket  34  connected for pivotal movement on the end of support bar  26  by way of pivot  32 . As shown in FIG. 9A, with footrest  16  in the retracted position, spring  44  is essentially on-center with pivot  32 . As footrest  16  is extended in the direction of arrow  166 , spring  44  moves to an over-center position as shown in FIG. 9C thereby automatically flipping footrest  16  into a horizontal leg supporting position. 
     As further shown in FIGS. 9A-9C, a pair of studs  170 ,  172  extend outwardly of the second portion  46  of bracket  34 . One of the studs  170  engages a groove  174  formed in the extension  30 . The other stud  172  engages a groove  176  formed in the end portion  28  of the footrest support bar  26 . The engagement of the stud  170  and the groove  174  allows a top edge  16   a  of footrest  16  to rotate outward about pivot  178  in the direction of arrow  168  from the furniture item when footrest  16  is in the retracted, vertically oriented position. Therefore, footrest  16  will pivot away from any object or body part entrapped between footrest  16  and the remainder of the furniture item when moving into the fully upright position. This pivoting motion occurs without interference from the remainder of furniture item  10  (FIG.  1 ). 
     Referring to FIG. 9C, the engagement of the stud  172  and the groove  176  allows downward movement of the footrest  16  in the direction of arrow  180  when footrest  16  is in the extended, horizontally oriented position. The extension  30  and footrest  16  rotate about pivot point  32 , the stud  172  traveling in the groove  176 . 
     Operating furniture item  10  to move between three different positions will be understood generally with reference to FIGS. 1-6. In the fully upright position shown in FIGS. 1 and 4, footrest  16  is maintained in a generally vertical orientation, but may pivot as shown in FIG.  9 B. To move furniture item  10  to the intermediate reclined or T.V. position shown in FIGS. 2 and 5, the seat occupant activated the drive assembly  112  to rotate the drive tube  110 . 
     As further shown in FIG. 5, the above-described movement of actuating structure  113  extends footrest support bar  26  and footrest  16  as best shown in FIG.  2 . Footrest  16  initially moves downward and then moves in an upward arc to the extended position. During extension, footrest  16  is also pivoted about pivot connection  32  to the generally horizontal orientation shown in FIG.  2 . This occurs by the over-center spring action discussed in connection with FIGS. 9A and 9C. During the extension of footrest support bar  26 , the S-shape of bar  26  in concert with the shape of slot  38  imparts a natural and comfortable movement to footrest  16  between the retracted and extended positions. To further move mechanism  20  into the fully reclined position shown in FIGS. 3 and 6, the seat occupant applies reward pressure against backrest  12  (FIG. 1) thereby pivoting backrest link  58  as shown in FIG.  3 . Through the backrest linkage  24  and the connection with base link  88  provided through link  72 , this forces seat link plate  22  and the attached link  94  and rollers  106 ,  108  to move in a forward direction. Rollers  106 ,  108  travel up tracks  84 ,  86 . The full reclining movement is stopped when rollers  106 ,  108  reach the ends of respective tracks  84 ,  86 . To move back into the intermediate reclined or T.V. position, the seat occupant releases their weight from backrest  12  and, to move into the fully upright position, the drive assembly  112  and the connected drive tube are rotated in a direction opposite to the actuating direction. This reverses the arc-shaped extension motion of footrest  16 . Also, toward the end of its retraction, footrest  16  will move briefly upward to tuck underneath seat  14  in a generally vertical orientation. 
     While the present invention has been illustrated by a description of a preferred embodiment and while this embodiment have been described in considerable detail in order to describe the best mode of practicing the invention, it is not the intention of applicant to restrict or in any way limit the scope of the appended claims to such detail. As some examples, the various linkage configurations, connections, etc., may differ significantly from mechanism to mechanism. A connection between two elements need not be a direct connection but may be a connection made through other structure. Also, with respect to the S-shaped section of the footrest support bar or the contemplated S-shaped track, although the preferred support bar is shown with an overall gradual, continuously curving S-shape, this term is meant to include other generally S-shaped configurations, including those having straight end portions, for example, or other curving portions. In combination with the curved track, the disclosed configuration is deemed to provide a desirable footrest movement. The configuration also functions well if the track is generally straightened except for a downwardly curved front end portion. Other combinations of curved track and support bar sections, for example, in combination with a linkage assembly may work as well while retaining the general inventive apparatus and method. Additional advantages and modifications within the spirit and scope of the invention will readily appear to those skilled in the art.