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:
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. 
     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. As one alternative construction, the mechanism may include a rocker element connected with the support structure to allow rocking of the furniture item by an occupant. 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, spring-biased 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 in a spring-biased manner 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 an elevational view of a schematically illustrated furniture item depicting a reclining mechanism constructed in accordance with the invention and shown from an inside perspective; 
     FIG. 2 is an elevational view of the reclining mechanism shown in FIG. 1, but illustrated in the intermediate reclined or T.V. position; 
     FIG. 3 is a fragmented elevational view similar to FIG. 2, but showing the mechanism in a fully reclined position; 
     FIG. 4 is an elevational view similar to FIG. 1, but deleting the schematically illustrated seat and backrest for clarity and showing the reclining mechanism from an outside perspective; 
     FIG. 5 is a fragmented elevational view similar to FIG. 4, but showing the mechanism in the intermediate reclined or T.V. position; 
     FIG. 6 is a fragmented elevational view similar to FIG. 5, but showing the reclining mechanism in a fully reclined position; and 
     FIGS. 7A-7C 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 bar  30  has a front end connected by a pivot  32  to a support bracket  34  affixed to footrest  16 . A second, opposite end of the S-shaped footrest support bar  30  includes a roller  36  connected for rotation therewith. 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  30  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  30  as it moves between retracted and extended positions as explained further below. A spring  44  is connected to a portion  46  of bracket  34  and further connected to a stud  48  extending from footrest support bar  30 . Spring  44  is disposed above pivot  32  between bracket  34  and support bar  30  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 FIG.  2 . Once in this position, footrest  16  can float in a spring-biased manner as shown in phantom in accordance with leg movement of the seat occupant. 
     Backrest linkage  24  includes a link  50  rigidly secured by fasteners  52  to a seat supporting tube structure  54 . A pivoting backrest link  56  is rigidly affixed to backrest  12  by fasteners  58  and includes a pivot  60  at one end secured to link  50 . 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  50 . A lower end of link  66  is connected with a further link  72  at a pivot connection  74 . Link  72  is connected at a front end to a base plate or link  76  by a pivot connection  78 . Another base link  80  is rigidly affixed to base link  76  and serves to support seat link  22  and the attached seat  14 . Forward and rearward movement of seat  14  with respect to base links  76 ,  80  is provided by front and rear rollers  82 ,  84  riding in respective front and rear tracks or slots  86 ,  88  contained in base link  80 . 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  84  also moves independently of front roller  82  when going from the fully upright position (FIG. 1) to the T.V. or intermediate reclined position (FIG.  2 ). Front roller  82  is connected to seat link  22 , while rear roller  84  is connected to a link  90  attached with seat link  22  by a pivot connection  92 . 
     As further shown in FIGS. 1 and 2, a rocker element  94  is rigidly affixed to base link  76  and allows rocking motion of the backrest  12 , seat  14  and footrest  16  with respect to base  1   8  when furniture item  10  is in the fully upright position shown in FIG.  1 . As further shown in FIG. 2, front and rear rollers  100 ,  102  are provided to prevent rocking motion when furniture item  10  is moved into the intermediate reclined or T.V. position. In the T.V. position, rear roller  102  will engage a ramp  104  affixed to base member  18  and front roller  100  will directly engage base member  18 . Rear roller  102  is connected to link  90 , while front roller  100  is connected to a link  106 . Link  106  is part of an overall linkage assembly which further includes links  108  and  110  connected so as to actuate roller  100  from the position shown in FIG. 1 to the position shown in FIG. 2 upon movement from the fully upright position (FIG. 1) to the intermediate reclined or T.V. position (FIG.  2 ). Link  106  is pivotally connected to base link  80  at pivot connection  112  and link  108  is connected by respective pivot connections  114 ,  116  to links  106  and  110 . Link  110  is pivotally connected at an opposite end to base link  80  by a pivot connection  118 . An extension spring  120  extends between an upper end of link  106  and a mid-portion of link  110 . This serves to pivot roller  100  to the disengaged position shown in FIG. 1 when mechanism  20  is moved from the intermediate reclined position or T.V. position to the fully upright position. 
     A drive tube or torque tube which is typically connected to a handle for operation by a seat occupant engages an upper surface of link  110 . It will be appreciated that actuation members or assemblies other than handles may be utilized. During movement from the fully upright position shown in FIG. 1 to the T.V. position shown in FIG. 2, seat link  22  will drop downward thereby pressing drive tube  130  against link  110  and rotating link  110  clockwise about pivot  118 . This moves link  106  and roller  100  to the locking position shown in FIG.  2 . Drive tube  130  rotates within a bushing contained within seat link  22 . Drive tube  130  further serves to actuate footrest  16  between the retracted and extended positions upon rotation by the seat occupant as will be described below. 
     FIGS. 4-6 respectively illustrate the fully upright, intermediate reclined or T.V. and fully reclined positions of mechanism  20  from an outside or opposite side perspective. This better illustrates the actuating structure  140  for footrest  16 . Actuating structure  140  preferably comprises links  142 ,  144 ,  146  connected for movement with a handle link  148 . Handle line  148  is affixed for rotation with drive tube  130  and drive tube  130  may be connected with a handle (not shown), as described above, which is rotated by a seat occupant. A link  150  interconnects actuating structure  140  with link  90  extending to the opposite side of mechanism  20 . More specifically, link  142  is pivotally connected to roller  36  at an upper end and connected to link  144  by a pivot connection  152  at a lower end. Link  144  is connected by a pivot connection  1   54  to seat link  22 . Another pivot connection  156  connects link  144  to link  150 . A pivot connection  157  connects an opposite end of link  150  to link  90 . A pivot connection  158  disposed approximately midway along link  144  connects link  144  with link  146 . Link  146  is connected to handle link  148  by a pivot connection  160 . An extension spring  162  is connected between link  146  and drive tube  130  and serves to lock actuating structure  140  in the position shown in FIG. 4 to thereby lock mechanism  20  in the fully upright position. 
     FIGS. 7A-7C illustrate the mounting and various possible movements of footrest  16  at the end of footrest support bar  30 . As previously mentioned, footrest  16  is mounted on a support bracket  34  connected for pivotal movement on the end of support bar  30  by way of pivot  32 . As shown in FIG. 7A, with footrest  16  in the retracted position, spring  44  is essentially on-center with pivot  32 . As footrest  16  is extended, spring  44  moves to an over-center position as shown in FIG. 7C thereby automatically flipping footrest  16  into a leg supporting position in the direction of arrow  166  (FIG.  7 A). In this position, spring  44  and pivot connection  32  allow a floating, pivoting motion in the clockwise direction of arrow  168  to provide more comfortable leg support to the seat occupant. As further shown in FIG. 7B, footrest  16  is further affixed to a mounting plate or other member  170  having a mounting portion  172 . Mounting portion  172  is connected by a pivot  174  to a portion  176  of footrest bracket  34 . A second spring  178  extends from a hole  180  in bracket portion  176  to a tab  182  disposed on mounting plate  170 . This provides the counterclockwise spring-biased movement referenced by arrow  184  in FIG.  7 B. This allows a rear edge  16   a  of footrest  16  to rotate outward from the furniture item with respect to a front edge  16   b  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 ). 
     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.  7 B. In this embodiment, furniture item  10  is shown as a rocker and may rock back and forth on element  94  when in the fully upright position. To move furniture item  10  to the intermediate reclined or T.V. position shown in FIGS. 2 and 5, the seat occupant rotates a handle affixed to drive tube  130  to thereby rotate handle link  148  clockwise, as viewed in FIG. 4, to the position shown in FIG.  5 . As further shown in FIG. 2, rollers  100 ,  102  move into engaged positions in front of and behind rocker  94  to prevent rocking motion in both the intermediate and fully reclined positions. The rotation of handle link  148  pulls link  146  forward and rotates link  144  counterclockwise about pivot  154 . At the same time, roller  36  attached with link  142  travels along slot  30  until reaching the front end slot  30  as shown in FIG.  5 . 
     As further shown in FIG. 5, the above-described movement of actuating structure  140  extends footrest support bar  30  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. 7A and 7C. During the extension of footrest support bar  30 , the S-shape of bar  30  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  56  as shown in FIG.  3 . Through the backrest linkage  24  and the connection with base link  76  provided through link  72 , this forces seat link  22  and the attached link  90  and rollers  82 ,  84  to move in a forward direction. Rollers  82 ,  84  travel up tracks  86 ,  88 , while roller  102  travels up ramp  104 . At the same time, drive tube  130  travels upward on link  110 . The full reclining movement is stopped when rollers  82 ,  84  reach the ends of respective tracks  86 ,  88 . 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 handle (not shown) 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.