Patent Publication Number: US-10758050-B2

Title: Torsion activator for motion furniture

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/675,352 filed Aug. 11, 2017, now U.S. Pat. No. 10,349,748, entitled TORSION ACTIVATOR FOR MOTION FURNITURE, which is hereby incorporated by reference in its entireties. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX 
     Not Applicable. 
     BACKGROUND 
     The present disclosure relates generally to furniture and more particularly to motion furniture with opposing side mechanisms. 
     Conventional motion furniture generally includes a frame having opposing side mechanisms joined together by cross-members that span between the side mechanisms. Each side mechanism includes a number of rigid linkage members connected at pivoting joints. During use, the side mechanisms may be actuated manually by a user or via an electromechanical drive system on the frame. When the side mechanisms are actuated, the linkage members pivot and/or translate relative to one another, leading to a desired movement of the furniture. For example, such desired movements of the side mechanisms often include rocking, reclining, or raising or lowering a footrest or ottoman. 
     The side mechanisms in conventional motion furniture are commonly mirror images of each other, and the side mechanisms generally move simultaneously in identical ranges of motion. The side mechanisms may be biased in an open or closed position using one or more springs or linkages to position the side mechanisms in a desired starting position. An activator is used in some furniture devices to provide a mechanism motion feature that may be biased in a desired open or closed position using a torsion spring. The activator may be manipulated by a user to selectively engage or disengage a feature on the side mechanism. Engagement of the activator by the user allows a user to move the side mechanism into a different position, for example when raising or lowering an ottoman or recliner feature. 
     Torsion activators are typically secured to one or both side mechanisms on a frame. For example, in some mechanisms, the activator is mounted on a flat seat plate. Some conventional torsion activators include an integral tab protruding from and end of the activator. The tab is positioned for insertion into a corresponding hole on the seat plate. The tab is first inserted into the hole in the seat plate with the activator oriented angled away from the seat plate surface. Once the tab is inserted, the activator is then rotated toward the seat plate so the activator becomes generally aligned in a plane parallel to the seat plate surface near the seat plate surface. Activator installation is a multi-step installation procedure requiring both an initial insertion and a subsequent rotation of the activator. 
     Once the tab is inserted and the activator is rotated, the opposite end of the activator may be aligned with a pre-formed socket on the seat plate. A fastener hole in the activator is aligned with the socket, and a threaded fastener is inserted through the fastener hole into a threaded engagement with the socket on the seat plate. The combination of the tab placement in the hole on the frame together with the fastener extending through the fastener hole on the activator into the socket on the frame operates to fix the activator in a rigid location relative to the frame. 
     During assembly of the frame, each side mechanism may be positioned upright or on a side in a jig or template at a desired orientation and spacing. Once positioned in the jig, frame components such as cross-members, springs and activators are attached to the side mechanisms using any suitable attachment mode. In some embodiments, fasteners are manually installed to attach the frame components to the side mechanisms. Some components may be manually attached using a mechanical interference fit. 
     Alternatively during frame assembly, one or more components may be installed using automated industrial robots having suitable end of arm tooling to affix the components to each side mechanism at the appropriate locations. 
     During both manual and automated frame assembly for motion furniture, it is generally desirable to reduce the number of physical steps any worker or automated robot must perform. Mechanism assembly step reduction optimizes the throughput and efficiency of the assembly line. For this reason, conventional side mechanisms are often configured in a suitable orientation for component attachment prior to packaging and delivery to the assembly line. Upon delivery to the assembly line, it is desirable for a worker or an automated robot to be able to grasp and lift the first and second side mechanisms and place each mechanism on a template or jig for component attachment without having to perform unnecessary operations on the side mechanism or the component. 
     During automated and manual assembly of side mechanisms for motion furniture frames using conventional activators, the torsion activators are difficult for workers and automated end of arm tooling to manipulate. Specifically, the multi-step tab insertion, rotation, hole alignment and fastener installation requires complex manipulation that is difficult for workers and for automated tooling to perform. 
     Difficulty in manual and automated torsion activator installation on seat plates or other components on a side mechanism often results in the inclusion of a manual step in an otherwise automated procedure for a user to manually insert the activator tab into the hole in the seat plate, rotate the activator into position, align the fastener hole with the socked, and insert the fastener into the threaded socket through the fastener hole. 
     The process of manually installing conventional activator components in side mechanisms during frame assembly is time consuming, requires additional steps in the assembly line, and reduces assembly line efficiency. 
     What is needed are improvements in component devices and methods for frame assembly in motion furniture. 
     BRIEF SUMMARY 
     This Brief Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     One aspect of some embodiments of the present invention provides a furniture apparatus including a torsion activator having an activator bracket including a proximal end and a distal end, with a torsion spring disposed between the proximal and distal ends. The activator bracket includes a first push fitting protruding from the proximal end configured for insertion in a corresponding first fitting hole in the mechanism, and a second push fitting protruding from the distal end configured for insertion in a corresponding second fitting hole in the mechanism. In some embodiments, the first and second push fittings include snap rivets integrally formed on the activator bracket. The activator also includes a moveable activator arm that is pivotable relative to the activator bracket. The activator arm may be actuated using any suitable actuation mode, including a tension or pull cable. A torsion spring is disposed between the activator bracket and activator arm to bias the activator in a desired initial position relative to both the activator bracket and the side member or mechanism component on which the torsion activator is mounted. 
     Another aspect of some embodiments of the present invention provides a torsion activator configured for installation on a linkage member such as a side mechanism of a furniture frame using a single translating motion to engage first and second push fittings (or press-fit fasteners) on the activator into corresponding holes in the side mechanism. 
     A further aspect of some embodiments of the present invention provides an improved torsion activator for motion furniture configured with a first and second push fittings to facilitate manual assembly by hand or automated assembly using one or more automated industrial robots. 
     Numerous other objects, advantages and features of the present disclosure will be readily apparent to those of skill in the art upon a review of the following drawings and description of a preferred embodiment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a detail elevation view of a side mechanism showing a conventional activator installed on a seat plate in a frame for motion furniture. 
         FIG. 2  illustrates a conventional torsion activator positioned for insertion on a side mechanism in a frame for motion furniture. 
         FIG. 3  illustrates a conventional side mechanism with openings for activator installation. 
         FIG. 4  illustrates an end view of a conventional torsion activator positioned for insertion on a side mechanism in a frame for motion furniture. 
         FIG. 5  illustrates an interior side view of a conventional torsion activator positioned for insertion on a side mechanism in a frame for motion furniture. 
         FIG. 6  illustrates an embodiment of a torsion activator configured for snap-fit installation on a side mechanism for motion furniture in accordance with the present disclosure. 
         FIG. 7  illustrates an end view of an embodiment of a torsion activator configured for snap-fit installation on a side mechanism for motion furniture in accordance with the present disclosure. 
         FIG. 8  illustrates an interior side view of an embodiment of a torsion activator configured for snap-fit installation on a side mechanism for motion furniture in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that are embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific apparatus and methods described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims. 
     In the drawings, not all reference numbers are included in each drawing, for the sake of clarity. In addition, positional terms such as “upper,” “lower,” “side,” “top,” “bottom,” etc. refer to the apparatus when in the orientation shown in the drawing, or as otherwise described. A person of skill in the art will recognize that the apparatus can assume different orientations when in use. 
     Referring now to the drawings,  FIG. 1  illustrates an example of a conventional side mechanism  10  for a frame on a piece of motion furniture. In a frame, side mechanism  10  would be positioned opposite a mirror image side mechanism, and multiple cross-members and a drive tube would span the gap between the opposing side mechanisms. During assembly, the opposing side mechanisms are generally aligned and held in place in spaced relation to each other on a jig or template. A worker or an automated robot would then install the horizontal drive tube and horizontal cross members to connect the opposing side mechanisms together. 
     As shown in  FIG. 1  and  FIG. 2 , a conventional torsion activator  20  is installed on side mechanism  10  of a piece of motion furniture. Activator  20  includes a proximal end  26  and distal end  28 . Activator  20  includes two main components. First, an activator bracket  46  is attached to a linkage member on the side mechanism  20 . In some embodiments, activator bracket  46  is secured to the seat plate  18  on side mechanism  10 . In other embodiments, activator  20  may be secured to any other suitable linkage member. Second, an activator arm  48  is pivotally attached to activator bracket  46 . During use, activator bracket  46  is maintained in position relative to side mechanism  10 , and activator arm  48  may pivot relative to activator bracket  46  about an activator pivot  58 . Activator pivot  58  in some embodiments includes a pivot point such as a rivet or rod passing between activator bracket  46  and activator arm  48 . 
     As shown in  FIGS. 1-3 , activator  20  is installed on side mechanism  10  in pre-formed holes in a linkage member on side mechanism  10 . For example, as seen in  FIG. 3 , seat plate  18  includes a first hole  22  and a second hole  32 . First hole  23  includes a threaded fastener hole defined in seat plate  18 . In some embodiments, first hole  23  is a threaded socket. Similarly, a second hole  32  is also defined in seat plate. Second hole  32  is a clearance hole having a rectangular profile in some embodiments. Activator  20  is installed on the side mechanism  10  by inserting corresponding structure through the first and second holes  23 ,  32  in some embodiments. 
     Referring further to  FIGS. 1-5 , conventional activator bracket  46  includes a tab  30  protruding from distal end  28  of activator  20 . Tab  30  is misaligned with the activator bracket body via an offset  31 , forming an “s” or “z” shape. Tab  30  is dimensioned and shaped to fit in second hole  32 . During installation of conventional activator  20  onto side mechanism  10 , tab  30  is first inserted into second hole  32  with activator bracket  46  oriented at an angle away from the plane of side mechanism  10 . Once tab  30  is installed in second hole  32 , activator bracket  46  may be angled toward side mechanism  10  such that activator bracket  46  becomes generally aligned in a plane parallel to seat plate  18 , as shown in  FIG. 1 . Due to offset  31 , tab  30  may be retained in second hole  32  when activator bracket  46  is pressed flush against seat plate  18 . 
     Referring further to  FIGS. 1-5 , proximal end  26  of activator bracket  46  is secured to side mechanism  10  using a fastener  24 . A fastener hole  22  is defined in the proximal end  26  of activator bracket  46 , and a fastener  24  extends through fastener hole  22 . Once tab  30  is placed in second hole  32 , fastener hole  22  on activator bracket  46  may be aligned with first hole  23  on a linkage member such as seat plate  18 . When fastener hole  22  is aligned with first hole  23 , a fastener  24  may be inserted through fastener hole  22  to engage a threaded socket on first hole  23 . Fastener  24  may be tightened using any suitable driver such as a socket driver or screw driver to secure fastener  24  in place. Fastener  24  includes any suitable fastener such as a socket head cap screw, hex screw, or other suitable conventional fasteners. 
     A torsion spring  50  is disposed between activator bracket  46  and activator arm  48 . Torsion spring  50  operates to bias activator arm  48  in a desired angular orientation relative to activator bracket  46 . As shown in  FIG. 1 , activator  20  may be manipulated using a cable tension system to selectively drive angular displacement of activator arm  48  relative to activator bracket  46 . For example, a cable mount hole  38  may be defined in side mechanism  10  spaced from first and second holes  23 ,  32 . A cable stop  40  is mounted in cable mount hole  38 . A cable housing  42  terminates at cable stop  40 . A flexible tension cable  44  travels through cable housing  42  and out of cable stop  40  toward activator  20 . A distal end of cable  44  is connected to activator arm  48  at a cable hole  36  defined on activator arm  48 . When cable  44  is pulled in a direction away from activator  20 , tension is applied to activator arm  48 , causing activator arm  48  to rotate about pivot  58 . The rotating motion of activator arm  48  causes activator flange  52  to approach and contact a linkage member on the side mechanism  10 . When cable  44  is pulled further away from activator  20 , the engagement between activator flange  52  and the linkage member drives a desired motion on the side mechanism relating to actuation of the motion furniture. 
     The general procedure of first inserting tab  30  into second hole  32 , then rotating activator bracket  46 , aligning fastener hole  22  with first hole  23 , and installing fastener  24  is a cumbersome procedure that is typically performed using a manual worker. Automation of this procedure with the conventional activator bracket hardware is difficult to achieve using end of arm tooling. 
     Referring now to  FIGS. 6-8 , an improved torsion activator  120  is provided as part of the present invention. Improved torsion activator  120  includes an activator bracket  146  and an activator arm  148 . Activator bracket  146  includes a proximal end  126  and a distal end  128 . Activator bracket  146  is configured for attachment to a linkage member on a side mechanism  10  using the pre-existing first and second holes  23 ,  32 . However, activator  120  is modified to allow installation in a push-fit application as opposed to the multi-step tab insertion and fastener attachment associated with the conventional activator described above and illustrated in  FIGS. 1-5 . 
     Improved activator  120  includes a first press-fit fastener, or first push fitting  122  and a second press-fit fastener  130  disposed on activator bracket  146 . First press-fit fastener  122  includes any suitable press-fit fastener. First press-fit fastener  122  is configured to be inserted linearly into first hole  23 . One or more retainer features such as tabs  132  are positioned on first press-fit fastener  122  to secure first press-fit fastener  122  in place and to keep the activator bracket  146  from inadvertently backing out of first hole  23 . 
     Similarly, a second press-fit fastener, or second push fitting  130  is disposed on distal end  128  of activator bracket  146 . Second press-fit fastener  130  i includes any suitable press-fit fastener. Second press-fit fastener  130  is configured to be inserted linearly into first second hole  32 . One or more retainer features are positioned on second press-fit fastener  130  to secure second press-fit fastener  130  in place and to keep the activator bracket  146  from inadvertently backing out of second hole  32 . 
     During use, activator  120  is installed on a side mechanism  10  for use as shown in  FIG. 1 . A cable tension system is utilized with torsion activator  120  to impart angular motion on activator arm  148 . For example, a tension cable is attached to activator arm  148  at a cable hole  136 . When the cable  44  is pulled, the cable motion causes activator arm  148  to pivot about activator pivot  158 , causing activator flange  152  to engage and drive motion in a corresponding linkage member. 
     A benefit of activator  120  is that it may operate similarly to conventional activator  20 , but is amenable to improved manual installation or automated installation using suitable end of arm tooling with an industrial robot. 
     As shown in  FIG. 7 , in some embodiments, second press-fit fastener  130  includes a “Christmas-tree” style rivet extending from activator bracket  146  toward the seat plate  18  of side mechanism  10 . Second press-fit fastener  130  is integrally formed on activator bracket  146  in some embodiments. Similarly, first press-fit fastener  122  may also be integrally formed on activator bracket  146 . As such, first press-fit fastener  122 , second press-fit fastener  130  and activator bracket  146  may be all integrally formed as a one-piece mechanism, for example as an integrally molded or injection molded part. By manufacturing activator bracket  146  with integral first and second press-fit fasteners extending toward seat plate  18 , cost of manufacture may be reduced. Additionally, by integrating first and second press-fit fasteners  122 ,  130  on activator bracket  146  pre-aligned in an orientation toward seat plate  18 , or in other words normal to the plane of activator bracket  146 , torsion activator  120  is improved to allow for a single-step automated installation of torsion activator  120  onto a side mechanism  10  or alternatively an improved manual installation of torsion activator  120  onto a side mechanism  10 . 
     As seen in  FIG. 8 , an alternative embodiment of an improved torsion activator  120  is shown, including a second press-fit fastener integrally molded with activator bracket  146  as a compressible barb fitting instead of a “Christmas-tree” style push rivet fitting shown in  FIG. 7 . The alternative embodiment in  FIG. 8  is just one example, and numerous other styles of press-fit fasteners may be utilized for first and/or second press-fit fasteners  122 ,  130  in other embodiments. 
     Thus, although there have been described particular embodiments of the present invention of a new and useful TORSION ACTIVATOR FOR MOTION FURNITURE, it is not intended that such references to particular embodiments be construed as limitations upon the scope of this invention.