Patent Publication Number: US-7708346-B2

Title: Reclining back mechanism for a seating unit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None. 
     BACKGROUND OF THE INVENTION 
     The invention relates to furniture such as a chair or sofa, such furniture pieces being referred to herein generally as seating units, and more particularly, to an improved mechanism for controlling the inclination angle of the back rest to the seat cushion. 
     Modern recliners exist that allow a user to recline the chair back relative to the seat. These existing recliners use mechanisms to control the inclination angle of the back. These mechanisms are housed internal to the seating and or back unit such that the mechanisms are hidden from view. However, these mechanisms are relatively complex and to some extent impose constraints on the furniture manufacture and transportation. Specifically, some of these mechanisms prohibit the disassembly of the back from the base frame, which holds the seat cushion, because the mechanisms extend into, and form a part of, the back. Additionally, these existing recliner mechanisms require a particular cross-beam configuration that is sized for each specific width of seating unit. This precludes manufacturing and assembling uniform components when producing a variety of sizes and styles of seating units. 
     The present invention pertains to a reclining back mechanism separable from the back rest. Significantly, the mechanism of the invention is constructed so that it is located within the stationary base area of the seating unit, thus enabling disassembly of the back rest from the base frame to facilitate, among other things, shipping and manufacture. Further, the present invention provides for a system of multiple lengths of interchangeable cross beams that allows for the manufacture of a variety of sizes, widths, and styles of recliners. 
     BRIEF SUMMARY OF THE INVENTION 
     A reclining back mechanism for a seating unit, where the seating unit has a stationary base and a reclining back. The stationary base has a pair of opposed side members, and the reclining back has a pair of opposed side frames. The reclining back mechanism has a pair of arms, a rearward transverse member, a forward transverse member, and an actuator. The arms are pivotably coupled to each of the opposed side members. Additionally, the arms have one end coupled to each respective opposed side frame, and another downwardly extending end. The coupling of the arms and side frames constitutes an attachment between the reclining back and the stationary base. This attachment is made by a mating component such that the mating component facilitates rapid assembly and disassembly of the reclining back from the stationary base. The rearward transverse member is made from generally rigid material and has opposed ends extending generally between the opposed side members. These opposed ends are coupled to the downwardly extending end of each respective arm. The downwardly extending end has multiple mounting holes that provide for selection of mounting positions between the arm and rearward transverse member. The forward transverse member is made from generally rigid material and has opposed ends extending generally between the opposed side members. These opposed ends are coupled to each respective opposed side member with a mounting bracket. The mounting brackets have multiple mounting holes that provide for a selection of mounting positions between the opposed side members and the forward transverse member. These multiple mounting hole locations are consistent in number and spacing with the multiple mounting hole locations of the downwardly extending ends of the arms. This configuration allows for the assembly of multiple stationary base widths while fixing the length of the transverse members. 
     The actuator is pivotably coupled on one end to the rearward transverse member, on the other end to the forward transverse member. Typically, the actuator is a gas cylinder with a release valve that is actuated by a release mechanism. The release mechanism includes a manual lever, a cable, and a release valve lever. When the release mechanism is not activated, the gas cylinder is rigid and holds the reclining back mechanism in a fixed orientation. A user of the seating unit may pull the manual lever of the release mechanism to adjust the reclining back to a reclined position. Pulling the manual lever rotates the lever and operates the cable, which in turn rotates the release valve lever. As the release valve lever rotates, it contacts the release valve, releasing the actuator and allowing movement of the reclining back mechanism. As a user exerts rearward force on the reclining back, the side frames cause the arms to pivot. This pivoting motion is carried through the downwardly extending ends of arms and swings the rearward transverse member forward toward the forward transverse member, compressing the actuator. As the user discontinues pulling of the manual lever, the actuator will arrest the position of the reclining back at a fixed position. A user of the seating unit may pull the manual lever of the release mechanism to return the reclining back to an upright position. Activating the release valve releases the actuator and allows its predisposed extension force to return the reclining back to the fully upright position. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       In the accompanying drawings which form a part of the specification and which are to be read in conjunction therewith, and in which like reference numerals are used to indicate like parts in the various views: 
         FIG. 1  is a diagrammatic perspective view of a seating unit; 
         FIG. 2A  is a diagrammatic partial perspective view of the reclining back mechanism with a lever control with certain parts being removed or broken-away for clarity; 
         FIG. 2B  is a view similar to  FIG. 2A , but with a manual cup actuator; 
         FIG. 2C  is a view similar to  FIG. 2A , but with a manual D-handle actuator; 
         FIG. 3  is an enlarged partial side elevation view of the gas cylinder-release assembly of the actuator; and 
         FIG. 4  is a view similar to  FIG. 2A  with the back reclined. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , it can be seen that the typical reclining chair  1  has a seat cushion  2 , a reclining back  3 , and a base section  4 . Base section  4  has a front  5 , a back  6 , and two sides  7 . Base section  4  supports the seat cushion  2  between the two sides  7 , and the reclining back  3  extends from the back  6  of the base section  4 . 
     As shown in  FIGS. 2A-2C , the mechanism  10  for adjusting the inclination of the reclining back  3 , as selected by the user, broadly includes a forward transverse member  20 , an actuator  30 , a rearward transverse member  40 , and a pair of arms  50 . The mechanism  10  is disposed between two mirror image opposed side frame members  21 , which support each of the two sides  7  of the reclining chair  1 . As can be seen, and as further described below, aside from the arms  50 , the mechanism  10  is disposed beneath the seat cushion  2 . 
     Returning to  FIG. 2A , the forward transverse member  20  is made from a generally rigid material, such as square steel tubing or square stock, and generally extends between the opposed side members  21 . Member  20  has opposed ends that fixedly connect to a mounting bracket  22 . Mounting bracket  22  includes multiple mounting hole locations  23  that allow the forward transverse member  20  to be attached at a selection of positions. This range of positions affects the spacing between the opposed side members  21  and provides for installation of the present mechanism  10  within a variety of base sections having different widths. An exemplary spacing of the mounting hole locations  23  will allow a particular forward transverse member  20  to assemble into a two-inch range of chair widths in one-half-inch increments. The multiple mounting hole locations  23  receive a fastener  24  that fixedly connects the forward transverse member  20  to the mounting bracket  22 . One fastener  24  is shown in  FIG. 2A , however, multiple fasteners  24  may be used. An exemplary configuration of the forward transverse member  20  connected to the mounting bracket  22  requires two fasteners  24 . The connection by fastener  24  may be made by hex-bolts and hex-nuts, or any other suitable fasteners which are well known in the furniture manufacturing industry. The other leg of bracket  22  is connected to the respective side frame member  21 . 
     The actuator  30  extends rearward from the forward transverse member  20  and is pivotably attached between the opposed ends of the forward transverse member  20  by a pivot assembly  25 . An exemplary configuration of the pivot assembly is a C-bracket  26  fixedly connected to the forward transverse member  20 . The C-bracket  26  receives a pin  27  through opposed holes, wherein the pin  27  is fixedly attached to the C-bracket  26 . As shown in  FIGS. 2A-2C , the preferred embodiment of the actuator  30  is a gas cylinder  33  that includes a rod end  32  and a head end  31 . An exemplary embodiment of the gas cylinder  33  is a compressed gas spring cylinder. Compressed gas spring cylinders will hold in a rigid position whether compressed or extended. This type of gas cylinder  33  will extend upon releasing stored, compressed gas from within the cylinder. It can be seen that the rod end  32  is directed forward toward the front  5  of the base section  4 . As best seen in  FIG. 3 , and as further described below, rod end  32  is coupled to assembly  25 , allowing the release of rod end  32  to return reclining back  3  to an upright position. 
     The head end  31  of the gas cylinder  33  is pivotably connected to the rearward transverse member  40  by a pivot assembly  45 . An exemplary configuration of the pivot assembly  45  is a C-bracket  46  fixedly connected to the rearward transverse member  40 . The C-bracket  46  receives a pin  47  through opposed holes, wherein the pin  47  is fixedly attached to the C-bracket  46 . It can be seen that the head  31  is directed rearward toward the back  6  of the base section  4 . A bore through the head end  31  receives the pin  47  that allows the actuator to pivot rotationally about the axis of the pin  47 . 
     The rearward transverse member  40  is made from a generally rigid material, such as square steel tubing or square stock, and generally extends between the opposed side members  21 . Member  40  has opposed ends that fixedly connect to the arms  50 . The arms  50  have a formed tab  52  that extends from a downward end  51 . Formed tab  52  is set at an angle such that a bottom surface  59  of the formed tab  52  is aligned with a mounting surface  48  of the rearward transverse member  40 . Formed tab  52  has multiple mounting hole locations  53  that allow the rearward transverse member  40  to be attached at a selection of positions. These multiple mounting hole locations  53  are consistent in number and spacing with the multiple mounting hole locations  23  of the mounting bracket  22 . An exemplary spacing of the mounting hole locations  53  will allow a particular rearward transverse member  40  to assemble into a two-inch range of chair widths in one-half-inch increments. The multiple mounting hole locations  53  receive a fastener  54  that fixedly connects the rearward transverse member  40  to the formed tab  52  of the arm  50 . One fastener  54  is shown in  FIG. 2A , however, multiple fasteners  54  may be used. An exemplary configuration of the rearward transverse member  40  connected to the formed tab  52  requires two fasteners  54 . The connection by fastener  54  may be made by hex-bolts and hex-nuts, or any other suitable fasteners which are well known in the furniture manufacturing industry. 
     The arms  50  have a downward end  51  and an upper end  58 . Between the downward end  51  and the upper end  58 , the arms  50  are pivotably coupled to the opposed side members  21  by a back pivot bracket  56 . The back pivot bracket  56  is fixedly connected to the opposed side members  21  by mounting hardware  104 . Additionally, the back pivot bracket  56  is pivotably connected to the arms  50  at pivot point  120  that provides an axis about which reclining back  3  is allowed to rotate. Arms  50  are formed from a sturdy material, such as stamped, formed steel. It should be understood that other suitable materials could also be used. 
     The upper end of the arms  58  includes one part of a knock-down fastener  57 . The knock-down fastener  57  includes a male component that allows the arms  50  to mate with a complimentary female component  61  that is fixedly connected to the opposed side frames  60 . The assembly of these components  57 ,  61  fixedly couples the arms  50  to the opposed side frames  60 . The opposed side frames  60  form a part of the reclining back  3 , and the arms are attached to the base section  4  at pivot point  120 . Therefore, the components  57  and  61  allow for the disassembly of the reclining chair  1  by a two point disengagement. Exemplary configuration of the knock-down fastener  57  are any of the knock-down fasteners known within the art. These knock-down fasteners facilitate the rapid assembly and disassembly of the reclining back  3  from reclining chair  1  and provide for the option of shipping the base section  4  as a separate unit from the reclining back  3 . 
     In use, a user of chair  1  can recline the reclining back  3  by activating a release valve  90  ( FIG. 3 ) provided with actuator  30 , and pressing rearwardly on the back. As the user exerts this rearward force, the reclining back  3  pivots about the pivot point  120 . This pivoting motion is carried through the downward ends  51  of arms  50 . This, in turn, exerts a forward force on member  40  and acts to compress rod  32  of actuator  30 . To adjust the reclining back  3  forward, the release valve  90  of actuator  30  is activated allowing its predisposed extension force to return the reclining back  3  to the fully upright position. 
     The release valve  90  is operated by a release mechanism. As shown in  FIG. 2A , one configuration of the release mechanism uses a manually actuated lever  80 . Lever  80  has a handle that extends above seat cushion  2  and a mounting section below seat cushion  2 . The mounting section is used to pivotably attach lever  80  to side member  21 . To achieve this coupling, a pivot bracket  81  is provided. Bracket  81  is fixedly coupled to side member  21 , such as by bolts, screws, or other attachment methods. The pivot point of lever  80  to bracket  81  is shown at pivot point  122  in  FIG. 2A . Bracket  81  has a section  124  extending perpendicularly to side member  21 . Section  124  serves as a connecting anchor for a spring  82 . The opposite end of spring  82  is connected with the mounting section of lever  80  below pivot point  122 . Spring  82  serves to return lever  80  to a forward position. Section  124  also serves as a mounting point for one end of a cable  88 . Specifically, cable  88  has an external end  83  extending from a conduit  84 . The cable is allowed to move axially within the conduit as is known to those of skill in the art. The external end  83  is coupled to the mounting section of lever  80  below the pivot point  122 . The end of conduit  84  adjacent section  124  is coupled to section  124 , such that the conduit is fixed and cannot move. 
     A length of cable  88  is provided to extend cable  88  to the release valve  90 . Cable  88  may be held in place in a desired location through various attachment mechanisms or grommets. The end of conduit  84  adjacent the release valve  90  has a mounting sleeve  85  sized to accommodate a snap-in attachment to a release mechanism, as further described below. Similarly, the cable  88  has an exposed external end  86  that is provided to apply force against the release lever  89 , which in turn transfers force to the release valve  90  when activated by the release mechanism. 
     Turning to  FIG. 3 , an enlarged view of the release mechanism at the end of rod  32  is shown. A cable mounting bracket is coupled to the end of rod  32 . Bracket  87  has a slot  126  ( FIGS. 2A-2C ) shaped and sized to facilitate a snap fit with mounting sleeve  85 . Bracket  87  is fixedly attached to a yoke  128 . Yoke  128  is generally U-shaped with two outwardly extending legs. Each of these legs has a hole to accommodate pin  27 . A lever  89  is positioned between the legs of yoke  128  and is pivotably connected between the legs with a pin  91 . Each of the legs of yoke  128  has a hole to accommodate pin  91 . The lever  89  pivots about pin  91  and is held in place with the external end  86  of cable  88 . Yoke  128  is also coupled to a C-bracket  26  through pin  27 . Lever  89  is formed with a slot  130 , which facilitates connection with cable  88 . More specifically, the external exposed end of cable  88  is placed through slot  130 , and the end  86  abuts lever  89 . As seen in  FIG. 3 , the release valve  90  is positioned between the legs of yoke  128 , and directly behind lever  89 . 
     In use, a user of chair  1  may pull lever  80  to recline or return the reclining back  3  to an upright position. Pulling lever  80  rotates the lever about point  122 , which engages end  83  of cable  88  to pull the cable itself through conduit  84 . This in turn pulls the end  86  against lever  89 , and rotates lever  89  about pin  91 . As lever  89  rotates, it contacts release valve  90 , releasing rod  32 . As the rod  32  is released, the actuator  30  exerts force on member  40  through arms  50  to reclining back  3  to return the back to an upright position. 
     As shown in  FIG. 2B , a second configuration of the release mechanism is shown as a manual cup actuator  100 . Similar to the previous configuration, the manual cup actuator  100  operates the release valve  90  whenever a lever  101  is pulled by the user. The lever  101  is connected to the external end  83  of cable  88  and is pivotably connected to the cup  102 . The cup  102  is fixedly coupled to the end of conduit  84  adjacent manual cup actuator  100  allowing the cable of cable  88  to pull axially through the conduit  84 . The manual cup actuator  100  can be mounted on any surface of the reclining chair  1 . 
     As shown in  FIG. 2C , a third configuration of the release mechanism is shown as a manual D-handle actuator  110 . The manual D-handle actuator  110  operates the release valve  90  whenever the D-handle  111  is pulled by the user. D-handle  111  is connected to the external end  83  of cable  88 . A D-handle bracket  112  is fixedly coupled to the end of conduit  84  adjacent manual D-handle actuator  110  allowing the cable of cable  88  to pull axially through the conduit  84 . Similar to the manual cup actuator  100 , the manual D-handle actuator  110  can be mounted on any surface of the reclining chair  1 . 
     Although three different configurations of the release mechanism have been shown, it should be understood that other release mechanisms could be used, and that the invention is not limited to those release mechanism shown and described. 
     As previously stated, a component of the actuator  30  is the gas cylinder  33 . The gas cylinder  33  biases the reclining back  3  to the upright position as seen in  FIGS. 2A-2C . The seat occupant reclines the chair by activating the release valve and exerting force on the reclining back  3 . The release valve  90  may be triggered by the user with either configuration of the release mechanism to release the rigid position of the gas cylinder  33 . Upon actuating the release mechanism, the external end  83  of cable  88  is pulled outward through the end of the external conduit  84 . At the same time, the internal cable end  86  is proportionately pulled toward the mounting sleeve end  85  of conduit  84 . This action pivots the release lever  89  about the pin  91  and creates a force on the release valve  90 . As the reclining back  3  is biased rearward, the arms  50  pivot about the back pivot bracket  56 . Additionally, this action rotates the rearward transverse member  40  toward the forward transverse member  20  thereby compressing the gas cylinder  33 . Thus, as force is exerted upon the reclining back  3 , the gas cylinder  33  bias must be overcome. When the reclining back  3  is forced into a desirable reclined position, see  FIG. 4 , the user discontinues actuating the release mechanism such that the release valve  90  deactivates, fixing the gas cylinder  33  in position. Fixing the gas cylinder  33  in position arrests the inclination at a specific rearward bias position. 
     Then, the release valve  90  may be triggered by the user with either configuration of the release mechanism to return the reclining back  3  to a fully upright bias. The release mechanism triggers the release valve  90  to release pressure from the head end  31  and allows the reclining back  3  to return from the specific rearward bias position to a fully upright bias. 
     Persons familiar with the field of the invention will realize that it may be practiced by various devices which are different from the specific illustrated embodiment. Therefore, it is emphasized that the invention is not limited only to this embodiment but is embracing of a wide variety of mechanisms which fall within the spirit of the following claims.