Abstract:
A headrest tilt mechanism is provided for installation on a chair. The mechanism includes a back insert that frames an area of the chair to be independently pivoted. A pair of spaced headrest tilts are coupled to the back insert, and pivotally coupled to the back frame of the chair. A lower connector tube is coupled to the back frame of the chair below the back insert. A linkage coupler is pivotally coupled to an upper member at an upper pivot point and is pivotally coupled an actuator at a lower pivot point. The upper member has a secured leg secured to the pair of spaced headrest tilts and a pivotal leg pivotally coupled to the linkage coupler. An actuator is pivotally coupled between the linkage coupler and the lower connector tube that can be actuated to pivot the headrest tilts from a closed to an open position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/114,166, filed on Feb. 10, 2015, entitled “HEADREST TILT MECHANISM.” This application also claims the benefit of U.S. Provisional Application No. 62/055,771, filed on Sep. 26, 2014, entitled “HEADREST TILT MECHANISM”. The teachings of U.S. Application Nos. 62/114,166 and 62/055,771 are hereby incorporated by reference in their entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     TECHNICAL FIELD 
     Embodiments of the present invention relate to headrest mechanisms, and particularly to headrest mechanisms for use on reclining seating units. 
     BACKGROUND OF THE INVENTION 
     Conventional recliner chairs typically incorporate mechanisms to move the chair into three basic positions: closed, with the footrest retracted and the back generally upright, a “TV position” with the footrest extended and the back generally upright, and reclined, with the footrest extended and the back in a reclined position. 
     One feature that may add to the comfort of users of these conventional recliners is a moveable headrest. The moveable headrest feature allows the head portion of the chair back to pivot with respect to the remainder of the back. This may increase the comfort of a person, especially in the reclined position, as rotation of the headrest provides supports the head of the user and can be adjusted to the most-comfortable position. 
     While moveable headrests have been provided, it is desirable to provide a simplified structure, capable of installation on any number of styles of chairs, while still providing the adjustment needed to enhance the comfort of those using the chair. 
     BRIEF DESCRIPTION OF THE INVENTION 
     A simplified headrest tilt mechanism is disclosed that is operable to move a headrest portion of a chair back between a closed position generally in line with a chair back, and an open position in which the headrest is pivoted with respect to the chair back. 
     Additional objects, advantages, and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       The present invention is described in detail below with reference to the attached drawing figures, wherein: 
         FIG. 1  is a perspective view of an exemplary headrest tilt mechanism in a closed position, with only a portion of a chair frame shown for clarity, in accordance with an embodiment of the invention; 
         FIG. 2  is a perspective view similar to  FIG. 1 , from a different angle; 
         FIG. 3  is a perspective view similar to  FIG. 1 , with the mechanism in an open position, and with the back frame post removed to show the pivot point; 
         FIG. 4  is a perspective view similar to  FIG. 3 , but showing the release mechanism in a released condition; 
         FIG. 5  is an enlarged view showing the relationship of the motor slide hinge, the motor slide bracket and the cam; 
         FIG. 6  is a perspective view showing an embodiment using a different motor; 
         FIG. 7  is a view similar to  FIG. 6 , from a different angle; 
         FIG. 8  is a perspective view of an exemplary headrest tilt mechanism in a closed position, with only a portion of a chair frame shown for clarity, in accordance with a different embodiment of the invention; 
         FIG. 8A  is an enlarged view of a portion of  FIG. 8  to show particular details of construction; 
         FIG. 9  is a perspective view of the headrest tilt mechanism of  FIG. 8 , with additional parts removed for clarity; 
         FIG. 10  is a perspective view of the headrest tilt mechanism of  FIG. 8 , shown in the open, or tilted, position; 
         FIG. 11  is a view of the headrest tilt mechanism of  FIG. 10 , shown as a perspective view from a different angle; 
         FIG. 12  is a perspective view of one side of an exemplary headrest tilt mechanism in a closed position, with only a portion of a chair frame shown for clarity, in accordance with a different embodiment of the invention; 
         FIG. 13  is a view of the headrest tilt mechanism of  FIG. 12 , shown from a different angle, and with portions shown as “see through” for clarity; 
         FIG. 14  is a side view of  FIG. 13 ; and 
         FIG. 15  is a perspective view of an exemplary headrest tilt mechanism in a closed position, with only a portion of a chair frame shown for clarity, in accordance with a different embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention generally relate to a moveable headrest or head tilt mechanism for use on a recliner chair or other item of furniture. With initial reference to  FIG. 1 , an exemplary headrest tilt mechanism  10  is shown that moves the head portion of the chair between the closed position, shown in  FIGS. 1 and 2 , to the open position, shown in  FIG. 3 . The mechanism  10  is installed into the chair by mounting it to a back frame post  12  that forms the frame for the back of the chair. Only one back frame post  12  is shown in the figures for clarity, but in practice, a second back frame post will be present to support the other side of the chair back. Only a portion of the chair frame is shown, but those with skill in the art would readily understand that back frame post  12  forms only a part of the entire chair frame. Mechanism  10  is mounted to back frame post through a back post spacer block  14 . Block  14  is rigidly secured to the inner face of the back frame post  12 . A back bracket  16  is then rigidly secured to the back post spacer block  14 , such as by screws or bolts, although other methods of attachment would work. Back bracket  16  extends forwardly and upwardly. A stop  18  is either formed in, or coupled to, back bracket  16  at the lower end of the back bracket  16 . A headrest tilt  20  is pivotally coupled to the upper end of back bracket  16  at pivot  22  (as shown in  FIG. 3 ). Headrest tilt  20  is shaped as shown with an upwardly extending leg  24  and an inwardly extending leg  26 . As shown, there are two headrest tilts  20 , one a minor-image of the other. A top connector tube  28  is coupled to each inwardly extending leg  26  to secure the two headrest tilts  20  together. The connector tube  28  may include a series of spaced holes along its length to allow for width changes in the chair back to which mechanism  10  is attached. A back insert  30  is coupled between the upwardly extending legs  24  of the headrest tilts  20 . The back insert  30  is a rigid frame that, in practice, will be finished with support, padding and a cover. 
     A bottom bracket  32  is coupled to the back frame post  12 , spaced downwardly from back bracket  16 . As shown, the mechanism  10  includes two bottom brackets  32 , each a minor-image of the other. A bottom connector tube  34  is rigidly secured to each bottom bracket  32  and forms a lower brace for the mechanism  10 . More specifically, a clevis  36  is coupled to the connector tube  34  such as by bolts, rivets or welding. The shaft  38  of a motor  40  is then pivotally coupled to the clevis  36 . The motor shown in the figures could also be any other type of motor, linear actuator or gas spring, capable of the movements described below. The upper end of motor  40  is pivotally coupled to back area of a motor slide hinge  42  at pivot  44 . Motor slide hinge  42  has an upper surface with a locating notch  46 , as best seen in  FIG. 5 . Additionally, motor slide hinge  42  includes a retaining finger  48  that extends upwardly. The retaining finger  48  operates to prevent the mechanism geometry from entering an over-center condition, retaining the stop pin  54  in the desired area. The forward area of motor slide hinge  42  is pivotally coupled to a motor slide bracket  50  at pivot  52 . Motor slide bracket  50  is generally L-shaped. One leg of the L is pivotally coupled to the motor slide hinge  42 . The other leg of the L is rigidly secured to the adjacent inward leg  26  of the headrest tilt  20  through connector tube  28 . A stop pin  54  is rigidly secured to the motor slide bracket  50 . Stop pin  54  is located to correspond with the notch  46  in the motor slide hinge  42 . 
     At least one of the inward legs  26  (or the top connector tube  28 ) is connected to at least one of the bottom brackets  32  (or the bottom connector tube  34 , or the back post  12 ) with an extension spring  56 . Spring  56  biases the mechanism  10  to the closed position shown in  FIG. 1 . The motor  40  is sized to overcome this spring force to move the mechanism  10  from the closed position to the open position. More specifically, if a user desires to move the mechanism from the closed position of  FIG. 1  to the open position of  FIG. 3 , he or she will engage the motor  40 . While not shown, the motor  40  is operably connected to a switch or control that is operable by the user. The control for the motor  40  may be separate from, or integrated with, other controls associated with the chair. The shaft  38  of the motor extends, overcoming the biasing force of spring  56  and causing an upward force at pivot  44 . This upward force moves the motor slide hinge  42  upwardly. As the motor slide hinge  42  moves upwardly, the stop pin  54  is rotated rearwardly and upwardly, caused by the upward force of motor slide hinge  42  and the pivot point  52 . This movement also results in the corresponding movement of the motor slide bracket  50 . The rotation of the motor slide bracket  50  operates to rotate the headrest tilt  20  about pivot  22 . So, the motor  40  is used to provide selected adjustment of the angular position of the headrest tilt  20  with respect to the back frame post  12 . To move the headrest tilt to the closed position, the motor controls are used to retract the shaft  38 , and the spring  56  operates to pull the headrest tilts  20  to the closed position, until the headrest tilt  20  abuts stop  18 . 
     Another feature of the mechanism  10  is the release configuration. As the headrest tilts  20  are moving to the closed position, objects may have moved into place behind the back insert  30 . If an object is present, the pivotal coupling of the motor  40 , motor slide hinge  42  and motor slide bracket  50  cooperate to allow the motor  40  to continue to operate, without imparting continued force to the rotation of the headrest tilts  20 . More specifically, if an object is behind the back insert  30 , it will operate to block movement of the headrest tilts  20 , effectively preventing rotation about pivot  22 . The motor  40  can continue to operate, moving pivot  44  downwardly. With the headrest tilts  20  prevented from movement, the motor slide bracket  50  will remain in place. The motor slide hinge  42  is still allowed to move, pivoting about pivot  52 . This effectively moves the motor slide hinge  42  away from the stop pin  54 , as seen in  FIG. 4 . The only remaining force acting against the object behind back insert  30  is imparted by the spring  56 . 
     The mechanism  10  has been described above in a “frame-within-a-frame” environment. In other words, the back insert  30  nests within or between the back frame posts  12 . The mechanism  10  could also be used in an environment where the back frame posts  12  extend only to approximately the area of pivot  22 , with the back insert configured to extend essentially across the width of the chair on which it is placed. 
     An embodiment of the mechanism  10  showing the use of a different motor  40 A is shown in  FIGS. 6 and 7 . The clevis  36 A is configured differently from clevis  36  to accommodate the motor  40 A. The remainder of the components of mechanism  10  is the same. As noted above, other motors, gas springs, or linear actuators could also be used in mechanism  10 . As would be understood by those in the art, each different motor, gas spring or actuator may require slight modification in the mounting arrangement. 
     A different embodiment of the mechanism  10  showing a slightly different configuration is shown in  FIGS. 8-11 . With initial reference to  FIG. 8 , the mechanism  10  is again mounted between a back frame post  12  and a back insert  78 . More specifically, a motor bracket  60  is coupled to the frame post  12 , such as by bolts, adhesives or screws, although other attachment mechanisms could certainly be used. Bracket  60  extends inwardly from the frame post  12  and has an upwardly extending tab that is coupled to a clevis  62  of a motor  64  at pivot  66 . The opposite end of motor  64  has an extending shaft  68  that is pivotally coupled to a motor slide hinge  70  at pivot  72 . Motor slide hinge  70  is shaped as shown and has a retaining notch  82 , as best seen in  FIG. 8A  (similar to retaining notch  46  of  FIGS. 1-5 ), and a retaining finger  84  (similar to retaining finger  48  of  FIGS. 1-5 ). The motor slide hinge  70  is pivotally coupled to a back bracket  74  at pivot  76 . Although not shown, the pivotal coupling can be made with a bolt, rivet or other pivotal attachment mechanism. Near this pivotal coupling, a cam  80  is fixed to the back bracket  74 . The cam  80  generally rests within the retaining notch  82 . The upper end of the back bracket  74  is fixedly coupled to the back insert  78 , such that movement of the back bracket  74  results in movement of the back insert  78 . As best seen in  FIG. 9 , the back bracket  74  is pivotally coupled to a side bracket  86  at pivot  88 . Note that side bracket  86  has an unused hole spaced from pivot  88 . Having two holes positioned in this location and geometry allows side brackets  86  to be used as either left-side or right-side interchangeably. With continued reference to  FIG. 9 , a locating stop  92  is coupled to back bracket  74  and protrudes outwardly toward side bracket  86 . In the closed position, stop  92  rests within a notch  94  in side bracket  86 . As best seen in  FIG. 9 , a side bracket  86  and a back bracket  74  are used to pivotally couple back frame post  12  to back insert  78  on the side opposite motor  64 . A spring  96  extends from back bracket  74  to a mounting tab  98  coupled to back frame post  12 . The operation of the mechanism  10  shown in  FIGS. 8-11  operates substantially similarly to the operation described with respect to  FIGS. 1-5  above, including the operation of the motor and spring return, use of the retaining finger, and the release operation. 
       FIGS. 12-14  show a mechanism  10  that is similar to that described above with respect to  FIGS. 8-11 , but showing a “split-back” configuration. The mechanism  10  of  FIGS. 12-14  has many of the same components as those described in  FIGS. 8-11 . In this configuration, however, the back frame is split into a lower back frame post  100  and an upper head rest frame  102 . The motor bracket  60  is coupled to the lower back frame post  100 . Instead of the back bracket  74  being coupled to the back insert  78 , the back bracket  74  is coupled to the upper head rest frame  102  via a spacer block  104 . This embodiment illustrates the use of mechanism  10  in a split-back configuration, as opposed to the frame within a frame configuration of  FIGS. 8-11 . The principle operation of the mechanism remains the same, but offers furniture manufacturers additional choices in styling. 
       FIG. 15  illustrates the basics of mechanism  10  as shown and described with reference to  FIGS. 8-14 , but showing the use of a different motor  110  (which is the same motor as shown and described with respect to  FIGS. 6 and 7  above).  FIG. 15  illustrates that a number of different motors can be used while retaining the majority of the mechanism. As shown, a different motor bracket  112  is used to mount motor  110  to the back frame post  12 . Additionally, the coupling between the motor  110  and motor slide hinge  70  may be slightly different, depending on the shaft configuration of the motor. 
     From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages, which are obvious and inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.