Abstract:
A seating unit that includes a linkage mechanism adapted to adjust between closed, extended, and reclined positions is provided. The linkage mechanism includes a linear actuator primarily coupled to a seat mounting plate for carrying out automated adjustment of the linkage assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    None. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    None. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention relates broadly to motion upholstery furniture designed to support a user&#39;s body in an essentially seated disposition. Motion upholstery furniture includes recliners, incliners, sofas, love seats, sectionals, theater seating, traditional chairs, and chairs with a moveable seat portion, such furniture pieces being referred to herein generally as “seating units.” More particularly, the disclosure relates to an improved linkage mechanism for use on motorized chairs and driven primarily from the seat mounting plate. The improved linkage mechanism accomplishes a zero-wall configuration with fewer parts and a more simplified assembly than existing mechanisms. 
         [0004]    Reclining seating units exist that allow a user to extend a footrest forward and to recline a backrest rearward relative to a seat. These existing seating units typically provide three basic positions (e.g., a standard, non-reclined closed position; an extended position (TV position); and a reclined position). In the closed position, the seat resides in a generally horizontal orientation and the backrest is disposed substantially upright. The seating unit includes one or more ottomans that are collapsed or retracted in the closed position, such that the ottomans are not extended. In the extended position, often referred to as a television (“TV”) position, the ottomans are extended forward of the seat, and the backrest remains sufficiently upright to permit comfortable television viewing by an occupant of the seating unit. In the reclined position, the backrest is pivoted rearward from the extended position into an obtuse relationship with the seat for lounging or sleeping, while the ottoman remains extended. 
         [0005]    Several modern seating units in the industry are adapted to provide the adjustment capability described above. However, these seating units require relatively complex linkage mechanisms to afford this capability. The complex linkage assemblies limit certain design aspects when incorporating automation, as well as adding weight and cost to the mechanism. As such, a more refined linkage mechanism that achieves full movement when being automatically adjusted between the closed, extended, and reclined positions would fill a void in the current field of motion-upholstery technology. 
         [0006]    Accordingly, embodiments of the mechanism pertain to a novel, simplified linkage mechanism that efficiently moves a seating unit among the various positions, driven primarily using the seat mounting plate. The linkage mechanism is constructed in a simple and refined arrangement in order to provide suitable function while overcoming the above-described, undesirable features inherent within the conventional complex linkage mechanisms. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Embodiments seek to provide a simplified linkage mechanism that can be assembled to a motor and that can be adapted to essentially any type of seating unit. In an exemplary embodiment, the compact motor in concert with the linkage mechanism can achieve full movement of the seating unit between the closed, extended, and reclined positions. The motor may be employed in an efficient and cost-effective manner to adjust the linkage mechanism and is coupled primarily to the seat mounting plate. 
         [0008]    Generally, the seating unit includes the following components: at least a first foot-support ottoman; a pair of floor rails in substantially parallel-spaced relation; a pair of seat mounting plates in substantially parallel-spaced relation, a seating support surface extending between the seat mounting plates; and a pair of generally mirror-image linkage mechanisms that interconnect the floor rails to the seat mounting plates. In operation, the linkage mechanisms are adapted to move the seating unit between a closed position, an extended position, and a reclined position. The linkage mechanisms are coupled to a motor or linear actuator assembly primarily through a coupling directly to the seat mounting plate. This connection to the seat mounting plate is much more direct than in previous seating units and allows elimination of parts and connections in comparison to previous seating units. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0009]    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: 
           [0010]      FIG. 1  is a perspective view of a mechanism for a seating unit in a closed position, with one side removed for clarity; 
           [0011]      FIG. 2  is a side view of the mechanism of  FIG. 1 ; 
           [0012]      FIG. 3  is a side view similar to  FIG. 2 , from the opposite side; 
           [0013]      FIG. 4  is a perspective view of a mechanism, similar to  FIG. 1 , but in the TV position; 
           [0014]      FIG. 5  is a side view of the mechanism of  FIG. 4 ; 
           [0015]      FIG. 6  is a side view similar to  FIG. 5 , from the opposite side; 
           [0016]      FIG. 7  is a perspective view of a mechanism, similar to  FIG. 1 , but in the fully reclined position; 
           [0017]      FIG. 8  is a side view of the mechanism of  FIG. 7 ; 
           [0018]      FIG. 9  is a side view similar to  FIG. 8 , from the opposite side; 
           [0019]      FIG. 10  is a perspective view of a mechanism for a seating unit in a closed position, with one side removed for clarity, similar to  FIG. 1 , but with a different drive tube assembly; 
           [0020]      FIG. 11  is a side view of the mechanism of  FIG. 10 ; 
           [0021]      FIG. 12  is a side view similar to  FIG. 11 , from the opposite side; 
           [0022]      FIG. 13  is a perspective view of a mechanism, similar to  FIG. 10 , but in the TV position; 
           [0023]      FIG. 14  is a side view of the mechanism of  FIG. 13 ; 
           [0024]      FIG. 15  is a side view similar to  FIG. 14 , from the opposite side; 
           [0025]      FIG. 16  is a perspective view of a mechanism, similar to  FIG. 10 , but in the fully reclined position; 
           [0026]      FIG. 17  is a side view of the mechanism of  FIG. 16 ; 
           [0027]      FIG. 18  is a side view similar to  FIG. 17 , from the opposite side; and 
           [0028]      FIG. 19  is a diagrammatic view of a seating unit using the mechanism of  FIGS. 1-18 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]      FIGS. 1-9  illustrate a first embodiment of a mechanism  10  for use on a motion seating unit  12 , as shown in  FIG. 19 . Seating unit  12  has a seat  14 , a backrest  16 , legs  18 , an ottoman  20 , and a pair of opposed arms  22 . The mechanism  10  couples the seat  14 , the backrest  16 , and the ottoman  20  together to move the seating unit  12  between closed, TV, and fully reclined positions, as is more fully described below. 
         [0030]    As shown in  FIGS. 1 ,  4 , and  7 , mechanism  10  is adjustable to three basic positions: a closed position ( FIG. 1 ), an extended position (i.e., TV position) ( FIG. 4 ), and a reclined position ( FIG. 7 ). Additionally, only one side of mechanism  10  is shown, with the other side being a mirror-image of the side shown and described.  FIG. 1  depicts the mechanism  10  adjusted to the closed position, which is a normal, non-reclined sitting position with the seat  14  in a generally horizontal position and the backrest  16  generally upright and in a substantially perpendicular position relative to the seat  14 . Note that  FIGS. 1-18  show the mechanism  10  with the outer parts of the seating unit  12  removed for clarity. In particular, the seat  14  is disposed in a slightly inclined orientation relative to the floor. When adjusted to the closed position, the ottoman  20  is retracted and is positioned below the seat  14 .  FIG. 4  depicts the extended, or TV, position. When the mechanism  10  is adjusted to the extended position, the ottoman  20  is extended forward so it is generally horizontal. However, the backrest  16  remains substantially perpendicular to the seat. Also, the seat  14  is maintained in generally the same orientation relative to the floor. Typically, the seat  14  is translated slightly forward and upward.  FIG. 7  depicts the fully reclined position. The backrest  16  is rotated rearward by the linkage mechanism  10 . However, the rearward movement of the backrest  16  is offset by a forward and upward translation of the seat  14  as controlled by the linkage mechanism  10 . The forward and upward translation of the seat  14  in embodiments of the present invention allows for “zero-wall” clearance. Generally, the “zero-wall” clearance is used herein to refer to space-saving utility that permits positioning the seating unit  12  in close proximity to an adjacent rear wall and other fixed objects. 
         [0031]    As described below, the linkage mechanism  10  comprises a plurality of other linkages that are arranged to actuate and control movement of the seating unit  12  during movement between the closed, extended, and reclined positions. These linkages may be pivotally interconnected. The pivotal couplings (illustrated as pivot points in the figures) between these linkages can take a variety of configurations, such as pivot pins, bearings, traditional mounting hardware, rivets, bolt and nut combinations, or any other suitable fasteners, which are well known in the furniture-manufacturing industry. Further, the shapes of the linkages and the brackets may vary, as may the locations of certain pivot points. It will be understood that when a linkage is referred to as being pivotally “coupled” to, “interconnected” with, “attached” on, etc., another element (e.g., linkage, bracket, frame, and the like), it is contemplated that the linkage and elements may be in direct contact with each other or other elements, such as intervening elements, which may also be present. Not all reference numerals are listed on all figures, for clarity, but the same parts numbered in one figure correspond to similar parts numbered in other figures. 
         [0032]    Generally, the linkage mechanism  10  guides the coordinated movement of the backrest, the seat, and the ottoman. In an exemplary configuration, these movements are controlled by a pair of essentially mirror-image linkage mechanisms (one of which is shown herein and indicated by reference numeral  10 ), which comprise an arrangement of pivotal interconnected linkages. The linkage mechanisms are disposed in opposing-facing relation about a longitudinally extending plane that bisects the recliner between the pair of opposed arms. As such, the ensuing discussion will focus on only one of the linkage mechanisms  10 , with the content being equally applied to the other complimentary linkage assembly. 
         [0033]      FIGS. 1-9  illustrate the configuration of linkage mechanism  10  in a first aspect, for a motorized, zero-wall clearance, seating unit  12 . Mechanism  10  has a pair of parallel, spaced sides, one left and one right, although only one side is shown in the figures for clarity. Each side of mechanism  10  includes a side rail  26  that extends from the front of the seating unit  12  to the back. Rails  26  are used to mount the mechanism  10  to the base of the seating unit  12  and operate as the base of the mechanism  10 . A rear pivot link  28  extends upwardly from the rail  26  and is pivotally connected to the rail  26  at a lower end thereof. Unless otherwise described differently, each of the rails, links, and brackets described herein are typically made of formed or stamped steel, but other materials with similar characteristics could be used. Rear pivot link  28  has an outward extension formed generally between its ends that functions to couple a rear cross tube  30  between the left and right mechanisms  10 . Rear cross tube  30  provides stability to the mechanism  10 . The upper end of rear pivot link  28  is pivotally coupled to a rear bell crank  32  at pivot  34 . Rear bell crank  32  is also pivotally coupled to a rear control link  36  at pivot  38 . Finally, rear bell crank  32  is pivotally coupled to a bridge link  40  at pivot  42 . As can be seen, rear bell crank  32  is somewhat triangularly shaped and connects the rear pivot link  28 , the rear control link  36 , and the bridge link  40 . As best seen in  FIG. 3 , a stop pin  33  is rigidly secured to rear bell crank  32  that operates to keep a seat mounting plate  48  (described below) in position as stop pin  33  moves along a notch  35  formed in seat mounting plate  48 . As best seen in  FIGS. 2 and 5 , rear bell crank  32  has another stop pin  37  that contacts rear pivot link  28  when the mechanism is in a closed position. 
         [0034]    The rear control link  36  is coupled on one end to the rear bell crank  32  at pivot  38 . It extends upwardly and rearwardly, and is pivotally connected to a back mounting link  44  at its other end, at pivot  46 . Rear control link  36  is thus pivotally connected between rear bell crank  32  and back mounting link  44 . Back mounting link  44  has a forward end that is pivotally coupled to a seat mounting plate  48  at pivot  50 . As best seen in  FIG. 2 , near pivot  50 , back mounting link  44  has a lower cam surface  52  that contacts a stop, or cam,  54  that is rigidly coupled to seat mounting plate  48 . The upper end of back mounting link  44  is used to couple the backrest  16  of seating unit  12  to the mechanism  10 . As back mounting link  44  pivots rearwardly, the backrest  16  is reclined. 
         [0035]    Returning to bridge link  40 , it can be seen that one end of bridge link  40  is pivotally coupled to rear bell crank  32  at pivot  42 . The opposite, forward end of bridge link  40  is pivotally coupled to an L-shaped, front lift link  58  at pivot  60 . As best seen in  FIG. 4 , bridge link  40  has an outward bend section  62  to provide clearance for other links of mechanism  10  to move properly and freely. The outer end of one leg of front lift link  58  is pivotally coupled to seat mounting plate  48  at pivot  64 . The outer end of the other leg of front lift link  58  is pivotally coupled to a front pivot link  66  at pivot  68 . Front lift link  58  is thus pivotally connected to bridge link  40 , seat mounting plate  48 , and front pivot link  66 . As best seen in  FIGS. 3 ,  6 , and  9 , front lift link  58  has a stop pin  59  rigidly secured thereto and extending therefrom, the importance of which is detailed below. 
         [0036]    Front pivot link  66  is thus coupled on one end to the front lift link  58  and is pivotally coupled on the opposite, lower end to side rail  26  at pivot  70 . A front cross tube  72  extends between the pair of front pivot links  66  and couples them together, generally adjacent the upper end of each front pivot link  66 . Like rear cross tube  30 , front cross tube  72  provides stability to the mechanism  10 , connecting the two sides together. A carrier link  74  is pivotally coupled to front pivot link  66  at pivot  76  generally midway between pivots  68  and  70 . Carrier link  74  extends rearwardly from pivot  76  and is coupled on its other end to a front bell crank  78  at pivot  80 . As with bridge link  40 , carrier link  74  has a bend section  82  to provide clearance for the other links of mechanism  10 . 
         [0037]    Front bell crank  78  has a somewhat boomerang shape, as shown. One end of front bell crank  78  is pivotally coupled to carrier link  74 . Generally, at the midpoint, front bell crank  78  is pivotally coupled to seat mounting plate  48  at pivot  84 . The opposite end of front bell crank  78  is pivotally coupled to ottoman drive link  86  at pivot  88 . As best seen in  FIG. 3 , the end of ottoman drive link  86  opposite pivot  88  is pivotally coupled to rear ottoman link  90  at pivot  92 . Rear ottoman link  90  is pivotally coupled at its top end to seat mounting plate  48  at pivot  94 . The lower end of rear ottoman link  90  is pivotally coupled to a top ottoman link  96  at pivot  98 . Rear ottoman link  90  has a notch  93  to accommodate stop pin  59  when the linkage is in a closed position. The top ottoman link  96  is part of the ottoman linkage and is pivotally coupled at its opposite end to an ottoman bracket  100  at pivot  102 . Ottoman bracket  100  is connected to and supports ottoman  20 . Near pivot  98 , top ottoman link  96  is pivotally coupled to a front ottoman link  104  at pivot  106 . One end of front ottoman link  104  is pivotally coupled to seat mounting plate  48  at pivot  108 . The other end of front ottoman link  104  is pivotally coupled to a lower ottoman link  110  at pivot  112 . Opposite pivot  112 , lower ottoman link  110  is pivotally coupled to ottoman bracket  100  at pivot  114 . As best seen in  FIG. 6 , front ottoman link  104  has a stop pin  116  rigidly secured near pivot  106 . Stop pin  116  stops the extension of the ottoman linkage at the desired location. 
         [0038]    Returning to seat mounting plate  48 , a drive tube mounting bracket  118  is rigidly secured generally about the midpoint of seat mounting plate  48 . As best seen in  FIG. 1 , drive tube mounting bracket  118  is used to secure a drive tube  120  between both seat mounting plates  48 . As seen in  FIG. 1 , drive tube  120  has a slight forward bend  122 . A connector link  124  is rigidly secured to drive tube  120  at its midpoint. The connector link  124  is used to pivotally couple the drive tube  120  to a motor  126 . Motor  126  extends between the drive tube  120  and a rear cross rail  128  that extends between the two side rails  26 . To facilitate that connection, a clevis  130  is formed or secured to rear cross rail  128 . A front cross rail  134  similarly extends between the two side rails  26  to connect the two sides of mechanism  10  together. The motor can be operated to extend a motor shaft  136 . Extension of the shaft  136  operates to move the linkage between the closed, TV, and fully reclined positions. 
         [0039]    More specifically, in operation, the motor  126  can be activated to extend shaft  136  when the mechanism  10  is in the closed position of  FIG. 1 . Extension of the shaft  136  operates to move the drive tube  120  in a forward direction. Due to the connection to seat mounting plate  48 , the movement of drive tube  120  moves seat mounting plate  48  in a forward direction as well. As can be seen in  FIGS. 3 and 6 , movement of seat mounting plate  48  causes a rotation of front bell crank  78  about pivot  84 , which in turn causes the pivotal connection between front bell crank  78  and ottoman drive link  86  to move forwardly. This movement drives ottoman drive link  86 , which in turn drives (as viewed from the perspective of  FIGS. 3 and 6 ) a counterclockwise rotation of rear ottoman link  90  about pivot  94 . As rear ottoman link  90  rotates, the ottoman bracket  100  is moved to the extended position shown in  FIG. 6  by the interconnection of links  90 ,  96 ,  104 , and  110 . The stop pin  116  prevents over extension of the ottoman linkage. 
         [0040]    As the seat mounting plate  48  moves forward, the seat translates forwardly, and downward, as rear pivot link  28  and front pivot link  66  rotate about their respective connections to side rail  26 . In this TV position, the back mounting link  44  remains in substantially the same orientation so that the back  16  remains substantially upright. 
         [0041]    Further activation of motor  126  causes additional forward force on seat mounting plate  48 , acting through drive tube  120 . The stop pin  116  prevents further extension of the ottoman linkage. As the seat mounting plate  48  is urged forwardly, front lift link  58  rotates and acts to lift seat mounting plate  48 . This further movement also causes a rotation of rear bell crank  32 , which pulls rear control link  36  forward and downward. As rear control link  36  rotates and moves, it causes back mounting link  44  to rotate about pivot  50 , thus acting to recline the back  16 . Because the seat mounting plate  48  moves forwardly as the mechanism  10  moves to the fully reclined position, the mechanism  10  affords a zero-wall clearance for the seating unit  12 . The direct connection of motor  126  to seat mounting plate  48  through mounting bracket  118  and drive tube  120  allows a more simplified motorized mechanism as compared to previous offerings. This simplification reduces the weight of the mechanism through removal of now unneeded parts, as well as reducing cost. 
         [0042]      FIGS. 10-18  illustrate an alternative mechanism  10  that is largely the same as that described above with respect to  FIGS. 1-9 . Mechanism  10  of  FIGS. 10-18  utilizes a different drive tube  142  and drive tube bracket  144 . As shown, drive tube  142  is a straight tube, as opposed to the bent drive tube  120  of  FIGS. 1-9 . Drive tube bracket  144  is fixedly coupled to seat mounting plate  48 , and includes a forward offset section  146  to properly position drive tube  142  and to allow connection of drive tube  142  to seat mounting plate  48 . The remainder of the links and connections remain the same, as does the movement of the mechanism  10 , and so the description is not repeated here. The links and connections are consistently numbered, with the exception of the drive tube  142  and drive tube bracket  144  (with offset section  146  as well). The alternative mechanism of  FIGS. 10-18  thus similarly drives the seating unit through a direct, fixed connection between the drive tube  142  and the seat mounting plate  48 . 
         [0043]    The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its scope. 
         [0044]    It will be seen from the foregoing that this invention is one well adapted to attain the ends and objects set forth above, and to attain other advantages, which are obvious and inherent in the device. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and within the scope of the claims. It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not limiting.