Patent Publication Number: US-2019167004-A1

Title: Motorized furniture headrest assembly for seating systems

Description:
BACKGROUND 
     Field of the Disclosure 
     This application relates generally to adjustable furniture and, more specifically, to motorized adjustment of headrests and lumbar features of seating systems. 
     Description of the Related Art 
     Recliner seating systems frequently include features to enhance the comfort of the user. For example, a seating system may include an actuatable headrest, foot rest, back deck, and/or lumbar feature. While various attempts have been made to produce motorized actuatable features in such seating systems, a drawback of many such systems is that the actuator mechanism is required to perform too much work to effect the desired adjustment of the actuatable feature. For instance, a movable headrest may have its actuation controlled by a linear actuator mounted to a side support strut of a headrest sub-assembly in the frame of a reclining seat. This linear actuator features a cam roller that is constrained within a curvilinear cam track having a fixed radius of curvature. 
     By mounting the linear actuator to the side support strut, in recliner seats having relatively wide headrests, it is found that the motion of the headrest imparted by the cooperation of the cam roller and curvilinear cam track tends to be uneven. That is, while the side of the headrest closest to the actuator undergoes desired angular motion according to the travel of the cam roller and curvilinear cam track profile, the side of the headrest farthest away from the actuator lags behind. This can, at a minimum, create an undesirable uneven appearance of the headrest when in an extended condition. At worst, this uneven motion of the headrest can lead to jamming of the hardware used to achieve the actuation of the headrest. 
     Another drawback of conventional motorized actuatable headrest systems is the amount of force and extent of travel the linear actuator has to exert in order to effect a desired movement of the headrest. 
     It would be desirable for an actuatable headrest system to employ a single actuator mounted in a manner that avoids the tendency for one side of the headrest to lag behind the other when undergoing angular movement. It would also be desirable for such a system to employ a design that minimizes the extent of travel and amount of energy that must be exerted by the linear actuator to effect the desired angular movement of the headrest. The manner in which these and other objects of the present disclosure are achieved will become evident with reference to the following summary of the disclosure, the drawings, and the detailed description of the preferred embodiments. 
     SUMMARY OF THE DISCLOSURE 
     An actuatable headrest and an actuatable lumbar support are provided in a headrest and lumbar support module of the present disclosure. This headrest and lumbar support module can be provided as a single unit that a reclining seat manufacture can readily install into a frame of a back deck of a reclining seat. By spacing actuator members of the headrest and lumbar support module inwardly from the side supports of the frame of the back deck, the actuator members need not be secured directly to the frame of the back deck. 
     Actuation of the headrest is accomplished by a motorized linear actuator member pivotally mounted at a first end and having a wheel unit disposed at a second end opposite the first end. The wheel unit includes a cam wheel that engages a cam surface of a cam track member, also referred to herein as a curvilinear track bracket, that is mounted to a cross-bar. The cross-bar defines a portion of a frame of the headrest. 
     The profile of the cam surface of the cam track has a non-constant radius of curvature. More specifically, the cam track is curvilinear, having at least a first portion which is straight and a second portion that is curved. As the cam wheel of the wheel unit of the motorized linear actuator member travels along the cam surface of the cam track member, the cam track member (i.e., the curvilinear track bracket), and thus the connected headrest frame, moves angularly. The profile of the cam surface of the cam track member permits the headrest to move angularly with less motion of the linear actuator member than conventional cam tracks having a curved shape of a single, constant radius of curvature. 
     Moreover, the cam track member does not form a cam track that encloses a cam roller. Rather, the cam surface, also referred to herein as a curvilinear track, is provided along an exposed edge of the curvilinear track bracket. This design permits the wheel unit to include cam wheel shrouds on both sides of the cam wheel, thereby preventing debris from interfering with smooth rolling motion of the cam wheel (also referred to herein as a roller wheel). The cam wheel shrouds also serve as bumpers to maintain contact between the roller wheel and the curvilinear track. 
     By mounting the headrest actuator and lumbar actuator toward the center of the headrest and lumbar support module, the headrest actuator is able to avoid imparting torsion to the headrest during actuation regardless of the width of the headrest. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         FIG. 1  is a front perspective view of a frame for a back deck of a reclining seat, including actuatable headrest and lumbar support mechanisms; 
         FIG. 2  is a front perspective view of a headrest and lumbar support module of the present disclosure that can be installed in a back deck frame; 
         FIG. 3  is a front perspective view of the frame for a back deck of  FIG. 1 , prior to installation of the headrest and lumbar support module of  FIG. 2 ; 
         FIG. 4  is a bottom and rear perspective view, with the frame of the back deck of the reclining seat partially broken away, of the headrest and lumbar support module; 
         FIG. 5  is a front perspective view of the headrest actuator assembly of the headrest and lumbar support module of the present disclosure; 
         FIG. 6  is an enlarged front perspective view of the headrest actuator assembly and a portion of a lumbar actuator assembly of the headrest and lumbar support module of the present disclosure; 
         FIG. 7  is a left perspective view of an actuator and cam track member of the headrest actuator assembly of the headrest and lumbar support module of the present disclosure; 
         FIG. 8  is a left perspective view similar to  FIG. 7  but from a different angle, of the actuator and curvilinear track member of the headrest actuator assembly of the headrest and lumbar support module of the present disclosure; 
         FIG. 8A  is a left perspective view of the actuator and curvilinear track member of the headrest actuator assembly in the identical position to that of  FIG. 8 , annotated to illustrate the piston arm of the actuator of the headrest actuator assembly fully extended at its maximum travel point and the associated roller wheel of the actuator of the headrest actuator assembly at a first end of its travel along the curvilinear track member; 
         FIG. 8B  is a left perspective view similar to  FIG. 8A , but illustrating the piston arm of the actuator of the headrest actuator assembly fully retracted at its minimum travel point and the associated roller wheel at a second end of its travel along the curvilinear track member; 
         FIG. 9  is a perspective view of a wheel unit of the headrest actuator assembly of the headrest and lumbar support module of the present disclosure; 
         FIG. 10  is a left perspective view of the headrest actuator assembly with the cam track member mounted to a cross-bar that defines a portion of the actuatable headrest; 
         FIG. 11  is a left front perspective view of the wheel unit of the headrest actuator assembly positioned at a first extent of its travel relative to the cam track member, which can track member is mounted to the cross-bar defining a portion of the actuatable headrest; 
         FIG. 12  is a side elevation view of the cam track member of the headrest actuator assembly; 
         FIG. 13  is a front and bottom perspective view of the cam track member mounted to the cross-bar defining a portion of the actuatable headrest; 
         FIG. 14  is a perspective view of the cam track member of the headrest actuator assembly; and 
         FIG. 15  is a top and rear perspective view of the cam track member of the headrest actuator assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following paragraphs, examples of various embodiments are described in detail and in doing so, reference will be made to a number of drawings in different figures. 
       FIG. 1  shows a front perspective view of a frame for a back deck of a reclining seat, including actuatable headrest and lumbar support mechanisms. Depicted is a motorized headrest and lumbar actuation system  20  with a wooden frame  30 , which combine to form an integrated wooden frame and motorized headrest and lumbar system  10 . The motorized headrest and lumbar actuation system  20  is typically a metallic subassembly that is assembled independent of the wooden frame  30 . These two main parts  20  and  30  are ultimately combined together, for example at the site of a reclining furniture manufacturer, to form the complete integrated wooden frame and motorized headrest and lumbar actuation system  10 . The main components of the motorized headrest and lumbar actuation system  20  include a first actuation mechanism  25 , which is used for moving the headrest and is also referred to as the headrest actuation mechanism  25 . Also included is a second actuation mechanism, used to move the lumbar actuation mechanism  26 , and also referred to as a lumbar actuation mechanism  26 . Typically, these two actuation mechanisms are similar and possibly even identical. However the two actuation mechanisms are mounted parallel to each other and facing opposite directions from one another, as illustrated in  FIG. 1 . The first actuation mechanism  25  moves the headrest part of the seat through pushing against an upper, headrest cross bar member  51  and consequently moving a hingedly-mounted headrest support mechanism  32 . The second actuation mechanism  26  moves a lumbar part of the seat through pushing against a lower, lumbar cross bar member  53  and consequently moving a lumbar support mechanism  33 . These two actuation mechanisms can move independent of one another and can be controller independently as well, such as using a two-feature control device (not shown). 
     The components of the integrated wooden frame and motorized headrest and lumbar actuation system  10  illustrated in  FIG. 1  are shown separately, and prior to integration with each other, in  FIGS. 2 and 3 . 
       FIG. 2  illustrates a front perspective view of a headrest and lumbar support module of the present disclosure prior to installation in a back deck frame. This headrest and lumbar support module is also referred to herein as the motorized headrest and lumbar actuation system  20 . It is an independently manufactured subassembly that is typically made from metallic bars that are welded together or alternatively connected to each other using nuts and bolts. It is also possible that both welding and bolting methods are used in combination with each other to fabricate this subassembly. The metallic components are usually coated with paint or other type of protective resin in order to minimize the effects of corrosion or wear and tear and consequently make it possible to extend the usable life of the product. 
     As illustrated in  FIG. 2 , there are two motorized actuation mechanisms  25  and  26  included in the motorized headrest and lumbar actuation mechanism  20 . As mentioned above, these two motorized actuation mechanisms  25  and  26  are independent of one another and their motion and control can be controlled independently. Alternatively, and if so desired, it is possible to synchronize the motion of these two independent motorized actuation mechanism using appropriate electronics and/or software applications, such that headrest and lumbar motion occurs simultaneously. The two motorized actuation mechanisms are mounted parallel to each other but their direction of motion is diametrically opposed from one another. The first motorized actuation mechanism  25  pushes upward against the headrest cross bar member  51  in order to move the headrest support mechanism  32 , while the second motorized actuation mechanism  26  pushes downward against the lumbar cross bar member  54  in order to move the lumbar support mechanism  33 . 
     It is desirable for an actuatable headrest system to employ a single actuator mounted in a manner that avoids the tendency for one side of the headrest to lag behind the other side when undergoing angular movement, such as tends to be the case with relatively wide adjustable headrests. Similarly, it is desirable for an actuatable lumbar system to employ a single actuator mounted in a manner that avoids the tendency for one side of the lumbar to lag behind the other when undergoing angular movement, such as with relatively wide lumbar supports. For this reason, it is desirable to mount the motorized actuator mechanisms  25  and  26  as close to the middle section of the actuation system as possible. Since in this motorized system there exist two separate actuator mechanisms, they are placed closed to each other near the middle point of the actuation system, but neither along a central axis, so as to have as advantageous an actuator placement as possible for both headrest and lumbar actuators, rather than a most-advantageous dead-center location for one, which would require a farther-off-center location for the other, although such an arrangement is still possible and is considered within the scope of the present disclosure, if the manufacturer desired such a compromise. 
     The two actuator mechanisms  25  and  26  are mounted on two separate, axially extending middle cross bar members  58  which are connected at one end to the upper cross bar member  52  and on the other end to the lower cross bar member  53 . The two middle cross bar members  58  are of the same length but are relatively shorter than the upper cross bar member  52  and the lower cross member  53  the two of which are approximately the same length. The two middle cross bar members  58  are connected to the upper cross bar member  52  and the lower cross bar member  53  in a perpendicular fashion. 
     Also connected in a perpendicular fashion to the upper cross bar member  52  and the lower cross bar member  53  are the two side cross bar members  59 . These metallic bar shaped members  52 ,  53 ,  58 , and  59  are attached to each other in a firm and secure fashion, either through being welded together, bolted together, or other suitable attachment techniques, or any combination thereof. The bar shaped members  52 ,  53 ,  58 , and  59  are integral components that form a core rectangular shaped bracket, onto which the other metallic components of the motorized headrest and lumbar actuator system  20 , including the two actuation mechanisms  25  and  26 , are attached. 
       FIG. 3  is a front perspective view of the frame for a back deck wooden frame  30  of  FIG. 1 . This wooden frame  30  is illustrated in  FIG. 3  by itself, prior to installation of the headrest and lumbar support module of  FIG. 2 , i.e., the motorized headrest and lumbar actuation system  20 . This wooden frame  30  includes several parts that are typically attached together using such mechanisms as screws, nails, glue, dove tails, or other similar wood-working connections or techniques frequently used in furniture frame manufacture. It is possible that a combination of connections and techniques are used. The components include two side members of the wooden seatback frame  35 , the upper cross member of the wooden seat back frame  36 , the backside cross member of the wooden seat back frame  36 , and the lower cross member of the wooden seatback frame  37 . Together, the components  35 ,  36 , and  37  form a box-like wooden frame that support a back side, or back deck, of the seat. As mentioned above, this wooden frame  30  is typically fabricated independent of the metallic motorized headrest and lumbar actuation system  20 . The two modular subassembly components  20  and  30  are each designed, formed, and fabricated as independent and separate subassembly modules and then are assembled together at a later stage of the manufacturing process in order to form the motorized headrest and lumbar actuation system integrated with the wooden frame  10  that is illustrated in  FIG. 1 . 
     This manufacturing method of separately fabricating independent separate modular subassemblies and then integrating them together at a later stage of the manufacturing process has a number of manufacturing advantages. In this fashion it is possible to subcontract for manufacturing the different parts of the final product, which in this case is the furniture seat, to different fabricators each with their particular skill set and are of expertise. In the example described in this disclosure, the wooden part  30  can be fabricated at one location by one manufacturer and the motorized headrest and lumbar actuation system  20  can be fabricated at another location by a different manufacturer. The final assembly to form the integrated wooden frame and motorized headrest and lumbar system  10  can be performed yet at third different place by a third group, or, more preferably, a supply of motorized headrest and lumbar actuation systems  20  can be delivered on a periodic basis to a location of the furniture manufacturer for integration as complementary wooden parts  30  are assembled to form reclining chairs. In this fashion it is possible to optimize production yield and time of production in addition to reducing inventory and minimizing the cost of manufacturing, which impacts the overall financial profitability of the product. It is also possible in this fashion to rapidly expand the production capacity of the manufacturing plant through outsourcing of the various components of the final product to various manufacturers or even outsourcing of the same component to a number of different manufacturers who could be competing against each other to minimize the production cost of the product. Repair or replacement of motorized headrest and lumbar actuation systems  20  is also facilitated by having the systems constructed as replaceable modules that are selectively securable to, and removable from, wooden frames  30 . 
       FIG. 4  illustrates the motorized headrest and lumbar actuation system  20  integrated with wooden frame  10 . But unlike  FIG. 1  that illustrates this same major component of the product in a front view perspective, the  FIG. 4  shows it in a back view perspective. In  FIG. 4  it is also indicated that a portion of the wooden frame is cut away, which is done for the sake of illustration only. The headrest support mechanism  32  is fully extended and can be seen in its angle of maximum displacement. The first actuation mechanism  25 , which is the headrest actuation mechanism, is shown in its fully extended position and at its maximum range of travel. The tip of this actuation mechanism, which is a roller wheel  45 , can be seen engaging a cam track member provided on the headrest cross bar member  51 , which cross bar member is a portion of the headrest support mechanism  32 . The engagement occurs along a special curvilinear track bracket  48  which will be described in greater detail below. There are two of these special curvilinear track brackets  48 . One of these two brackets  48  is connected to the tip of the first actuation mechanism  25  and the other is connected to the tip of the second actuation mechanism  26 . 
     Also illustrated in  FIG. 4  is the back view of the second actuation mechanism  26 , which is the lumbar actuation mechanism that is used to push against the lumbar cross bar member  54  and as a result extending the lumbar support mechanism  33 . In  FIG. 4 , the actuation mechanism  26  is extended only partially, and is shown positioned approximately at its mid-point of its travel range. The lumbar support mechanism  33  is extended partially and is shown positioned approximately at the mid-point of the range of its angular travel. Also visible is the second special curvilinear track bracket  48 , which is used to connect the tip of the second actuation mechanism  26  to the lumbar cross bar member. 
     Also visible in  FIG. 4  are the upper cross bar member  52 , the lower cross bar member  53 , and the two side cross bar members  59 . These metallic bar members  52 ,  53 ,  58 , and  59  that are attached to each other in a firm and secure fashion either through being welded together, bolted together, or other suitable attachment techniques, are the integral components that form a core rectangular shaped bracket onto which the other metallic components of the motorized headrest and lumbar actuator system  20  are attached, including the two actuation mechanisms  25  and  26 . This core bracket, which resembles a rectangle with two rounded corners, is illustrated in this back perspective view of  FIG. 4 . 
       FIG. 5  is an enlarged view of the motorized headrest and lumbar actuation system  20  of  FIG. 2  with some components omitted from this drawings for clarity and so as to provide better visibility of the other components. Illustrated is the headrest support mechanism  32  in its fully extended position and positioned at its maximum range of travel. Visible is the first actuation mechanism  25  which is the headrest actuation mechanism that is used to move the headrest support mechanism  32 . The actuation mechanism  25  is shown in this drawing fully extended and at its maximum range of travel. The tip of this actuation mechanism  25  is connected to the headrest cross bar member  51  through a special interconnecting curvilinear track bracket  48  which will be described in greater detail, below. The second actuation mechanism  26  of  FIG. 2  is omitted to better show the two middle cross bar members  58  which are two of the bar elements that connect the upper cross bar member  52  to the lower cross bar member  53 . The two actuation mechanisms  25  and  26 , with the item  25  omitted, are mounted onto these two middle cross bar members  58 . 
     Also connecting the upper cross bar member  52  to the lower cross bar member  53  are the two side cross bar members  59 . This core bracket which has a rectangular shape with two curved corners and it serves as the chassis which forms the base frame of the entire motorized headrest and lumbar actuation system  20  illustrated in its entirety in  FIG. 2 . 
     Turning to  FIGS. 6-15 , the interaction of the first actuation mechanism  25  with the curvilinear track bracket  48  secured to the upper cross bar member  51  (and thereby associated with the headrest support mechanism  32 ) will now be described. It will be appreciated that the composition of the second actuation mechanism  26  is the same or sufficiently similar to the first actuation mechanism  25 , and the interaction of the second actuation mechanism  26  with the other curvilinear track bracket  48  secured to the lumbar cross bar member  54  (and thereby associated with the lumbar support mechanism  33 ) is similar to that of the first actuation mechanism  25  with the curvilinear track bracket  48  secured to the upper cross bar member  51 , so detailed discussion lumbar actuation mechanism is omitted for the sake of brevity. 
     The first actuation mechanism  25  includes, as part of the headrest actuation mechanism, a receiver housing  41  of the actuation mechanism, a receiver collar  42  of the actuation mechanism, which serves to support the receiver housing  41  of the first actuation mechanism  25  on the upper cross bar member  52 . The first actuation mechanism  25  further includes a piston arm  43  that is telescopingly mounted in the receiver housing  25 . A first actuation motor  27  is provided on an actuator housing connector bracket  56 . The actuator housing connector bracket  56  supports an actuator connector  55  that hingedly engages an actuator mounting bracket  54  secured to an associated one of the middle cross bar members  58 . A hinge pin (HP) secures the actuator connector  55  to the mounting bracket  54 . 
     The actuation motor  27  drives gearing (not shown) within the receiver housing  41  to selectively extend or retract the piston arm  43  in a known manner, such that detailed description of the architecture of the interior of the actuation mechanism  25  is omitted. A roller housing  46  is mounted, preferably by a threaded connecting region  49 , to an engagement end of the piston arm  43 , opposite from the end of the piston arm  43  that is entirely contained in the receiver housing  41 . 
     The roller housing  46  rotatably supports a cam wheel, also referred to herein as a roller wheel  45 , on a roller axle pin  47  that extends between two cam wheel shrouds WS 1  and WS 2  of the roller housing  46 . The cam wheel shrouds WS 1  and WS 2  preferably have at least one dimension in a plane normal to an axis of rotation of the roller wheel  45  that is greater than a diameter of the roller wheel  45 . The cam wheel shrouds WS 1  and WS 2  serve to isolate an interior of the roller wheel  45  and an exterior of the roller axle pin  47  from debris, such as sawdust or loose padding from the furniture article in which the motorized headrest and lumbar actuation system  20  is deployed, and also serve as boundaries or bumpers to maintain the roller wheel  45  in contact with the curvilinear track  61  of the curvilinear track bracket  48  by preventing lateral disengagement of the roller wheel  45  from the curvilinear track  61 . 
     The curvilinear track bracket  48  includes at least a first mounting plate  66 , to secure the curvilinear track bracket  48  to the headrest cross member  51 . As illustrated in  FIGS. 12-15 , the curvilinear track  61  has a non-constant radius of curvature. Preferably, the curvilinear track  61  includes at least a linear section  62  and a curved section  63 , the curved section  63  having a gradual curvature (i.e., a wide radius of curvature). At an end of the linear section  62  of the curvilinear track  62  opposite the curved section  63 , the curvilinear track  61  is preferably provided with a curved end  64 , having a relatively sharp curvature (i.e., a smaller radius of curvature than the curved section  63 ), thereby defining a first end stop that serves to prevent the roller wheel  45  of the first actuation mechanism  25  from losing contact with the curvilinear track  61  of the curvilinear track bracket  48 . The curved section  63  of the curvilinear track  62  serves as the other end stop of the curvilinear track  61 .  FIGS. 8A and 8B  illustrate the interaction of the linear actuator and the curvilinear track  61  at two extremes, with  FIG. 8A  illustrating the piston arm  43  of the first actuation mechanism  25  of the headrest actuator assembly fully extended at its maximum travel point and the associated roller wheel  45  of the actuator of the headrest actuator assembly at a first end of its travel along the curvilinear track  61 , and  FIG. 8B  illustrating the piston of the first actuation mechanism  25  fully retracted at its minimum travel point and the associated roller wheel at a second end of its travel along the cam track member. 
     As the roller wheel  45  of the actuator of the headrest actuator assembly travels along the curvilinear track  61 , the curvilinear track bracket  48  is urged up or down, imparting angular movement to the upper cross bar member  51  to which the curvilinear track bracket  48  is secured, thereby imparting angular movement to the headrest.