Abstract:
The present invention describes the assembly structure of a massage device for a massage chair. The assembly structure includes an assembly frame that is divided into a first, second and third frame region. The first frame region is adapted to receive the assembly of a patting actuator block, the second frame region is adapted to receive the assembly of a sliding actuator block, and the third frame region is adapted to receive the assembly of a kneading actuator block. The massage device formed by the assembly of the different actuator blocks on the assembly frame has a reduced volume, and is easy to disassemble for repair or maintenance.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention generally relates to a massage device used in a massage chair, and more particularly to an assembly structure that is able to reduce a volume occupied by the massage device. 
         [0003]    2. The Prior Arts 
         [0004]    Presently, there is an increasing consumer demand for all kinds of healthcare products. As a result of this trend, massage chairs have been developed for home usage. In use, the massage chair may be operated to apply various massage movements on diverse regions of the user&#39;s body to relieve fatigue and promote blood circulation. As the design of the massage chair advances, more sophisticated functionalities are developed to provide enhanced massage experience to the user. As a result, the construction of the massage mechanism that is incorporated in the back rest of the massage chair becomes more complex, and requires a larger volume for its assembly. This usually leads to the following disadvantages usually encountered in conventional massage chairs: 
         [0005]    (1) The larger volume required for mounting the massage mechanism results in an increased size of the whole massage chair, which may not be compatible with the limited usage space available in urban habitation. 
         [0006]    (2) Because the massage mechanism becomes more complex and incorporates more component parts, maintenance and repair operations are more difficult to achieve. In certain conventional constructions, the component parts for the massage device may even be assembled at dispersed positions in the interior of the back rest. As a result, complex and time-consuming disassembly tasks are usually necessary during repair operations, which lengthen the service time. 
         [0007]    Conventionally, the massage device in a massage chair has the following three functionalities: (1) the massage device is able to slide up and down to apply a massage action to various regions of the user&#39;s back; (2) a core of the massage device usually includes two massage rollers capable of moving toward and away from each other to apply a kneading movement on the user&#39;s back; (3) the two rollers in the core of the massage device are able to apply a patting movement on the user&#39;s back. 
         [0008]    To achieve the foregoing functionalities, the manufacturer must provide the following three structures: 
         [0009]    (1) a first actuator structure adapted to slide the massage device up and down so as to push other actuator blocks, wherein the up and down movements are mainly achieved via a screwed shaft or toothed rail; 
         [0010]    (2) a second actuator structure adapted to cause the massage rollers to apply a kneading movement, wherein the kneading movement is achieved by a construction that includes an eccentric portion provided on a driven end of a swaying arm coupled to each of the rollers, which enables each of the rollers to perform alternated left and right movements when the driven end rotates; and 
         [0011]    (3) a third actuator structure adapted to cause the massage rollers to apply a patting movement, wherein the patting movement is achieved by a construction that includes a multi-axes transmission shaft coupled to each swaying arm and rearward provided with an eccentric portion at a shaft hole region, which enables each massage roller to perform a patting movement. 
         [0012]      FIG. 1  illustrates a conventional massage device  90  that may be incorporated in a massage bed. The illustrated structure was also described in U.S. Pat. No. 7,029,453 B2, filed by the same applicant of the present application. The massage device  90  integrates the same three actuating functionalities described above in one frame  91 . One side of the frame  91  is mounted with a first actuator block  97  adapted to perform up and down sliding movements. The first actuator block  97  includes a decelerator device  98  configured to cause a transmission shaft to roll and perform up and down movements on a toothed rail  60  via two gears (not shown) coupled to the two ends of the transmission shaft and engaging with the toothed rail  60 . A central region of the frame  91  includes a second actuator block  92  adapted to apply kneading movements. The second actuator block  92  includes a decelerator device  93  coupled to a swaying arm that is connected to each set of massage rollers  941  and has an eccentric portion enabling each set of massage rollers  941  to perform kneading movements. Another side of the frame  91  opposite the side of the first actuator block  97  is mounted with a third actuator block  95  adapted to apply patting movements. The third actuator block  95  includes a decelerator device  96  provided with an eccentric portion and coupled to a multi-axes transmission shaft  961 . The multi-axes transmission shaft  961  is also coupled to the second actuator block  92 , so that the third actuator block  95  can be operated to cause patting movements transmitted to the second actuator block  92 . 
         [0013]    While the approach illustrated in  FIG. 1  attempts to integrate the various actuator blocks in one frame  91 , the placement of the different component parts is still dispersed and fails to provide a dense structural assembly that facilitates repair operations. 
       SUMMARY OF THE INVENTION 
       [0014]    The present invention provides an assembly structure for a massage device of a massage chair that can overcome the foregoing issues of a large volume requirement for receiving a complex structure of the massage device. 
         [0015]    In one embodiment, a massage device of a massage chair comprises an assembly frame formed from a plate that is bent to define a first frame region, a second frame region and a third frame region. Each of the frame regions is provided with assembly holes and slots adapted to receive the assembly of one of the kneading actuator block, patting actuator block and sliding actuator block. More particularly, the first frame region receives the assembly of the patting actuator block having the eccentric portion, the axis of a driving motor and the axis of a decelerator device in the patting actuator block positioned parallel and above each other over the first frame region. The second frame region includes a second surface that is offset at a different level from a first surface of the first frame region so as to form a second accommodating space. In a same manner, the third frame region includes a third surface that is offset at a different level from the first surface of the first frame region so as to form a third accommodating space. The second frame region is assembled with the sliding actuator block having two sides respectively provided with a gear and a roller capable of rotating on a toothed rail. In the sliding actuator block, the axis of the driven end of the decelerator device is disposed above the axis of the driving motor, both axes being perpendicular to the second surface. In addition, the axis of the driven end of the decelerator device and the axis of the driving motor in the sliding actuator block respectively pass through assembly openings in the second surface to be received in the second accommodating space. The third frame region is assembled with the kneading actuator block also provided with an eccentric portion. The assembly direction of the kneading actuator block is opposite to that of the sliding actuator block, the driving motor of the kneading actuator block being placed at an upper position whereas its decelerator device is placed at a lower position. In addition, the axes of both the driven end of the decelerator device and the driving motor are also perpendicular to the third surface, and respectively pass through assembly openings in the third surface to be received in the third accommodating space. 
         [0016]    The above assembly structure provides at least the following advantages: 
         [0017]    (1) The whole massage device can be assembled with the assembly frame with one simple operation performed on a same assembly line, and repair operations are facilitated as the disassembly of the massage device is easier to achieve. 
         [0018]    (2) The configuration of the assembly frame enables a symmetrical placement of the patting actuator block, sliding actuator block and kneading actuator block, and also is able to stack the driving motor and the decelerator device of each actuator block in a compact space. Because the assembly volume is used in the most efficient manner, the total volume occupied by the massage device can be effectively reduced. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    The present invention will be apparent to those skilled in the art by reading the following detailed description of a preferred embodiment thereof, with reference to the attached drawings, in which: 
           [0020]      FIG. 1  is a perspective view of a conventional structure of a massage device; 
           [0021]      FIG. 2  is a perspective view partially illustrating an assembly structure of a massage device incorporated in a massage chair according to one embodiment of the present invention; 
           [0022]      FIG. 3  is an exploded view illustrating an assembly structure of a massage device incorporated in a massage chair according to one embodiment of the present invention; 
           [0023]      FIG. 4  is a perspective view illustrating the assembly structure of the massage device according to one embodiment of the present invention; 
           [0024]      FIG. 5  is a front view of the assembled massage device according to one embodiment of the present invention; 
           [0025]      FIG. 6  is a top view of the assembled massage device according to one embodiment of the present invention; 
           [0026]      FIG. 7  is a right side view of the assembled massage device according to one embodiment of the present invention; 
           [0027]      FIG. 8  is a rear view of the assembled massage device according to one embodiment of the present invention; 
           [0028]      FIG. 9  is a rear perspective view of the assembled massage device according to one embodiment of the present invention; and 
           [0029]      FIG. 10  is a perspective view illustrating the massage device incorporated in the back rest of a massage chair according to one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    The following description in conjunction with the accompanying drawings set forth embodiments for achieving a door lock provided with a large handle. 
         [0031]      FIG. 2  is a perspective view of the assembly of a massage chair  80 . As described previously, the volume occupied by the back rest of the entire massage chair  80  can be reduced when an efficient mounting space is provided for the assembly operation. According to an embodiment of the invention, a massage module  1  of the massage chair  80  is disposed on a toothed rail  60 . Driven by a gear, the entire massage module  1  is able to slide up and down on the back rest of the massage chair  80 . After the assembly of the massage module  1  is completed, a front end of the massage module  1  has a protective lid  70  provided with two slots through which massage rollers are able to protrude outward to apply a massage action. The protective lid  70  is of a well-known construction whose description is omitted herein. 
         [0032]      FIG. 3  is an exploded view of an embodiment of the present invention. The present invention includes an assembly frame  10  as main structure. The assembly frame  10  is a generally U-shaped plate comprising a first frame region  11 , a second frame region  12  and a third frame region  13 . The first frame region  11  has a larger surface area, and includes a first surface  111  provided with a plurality of assembly holes. The second frame region  12  and the third frame region  13  are located at two opposite sides of the first frame region  11 . The second frame region  12  includes a set of second surfaces  123 / 124  defining an L-shaped profile, whereas the third frame region  13  includes a set of third surfaces  133 / 134  also defining an L-shaped profile. Moreover, the second surface  123  and third surface  133  are located at a level offset from the first surface  111  so as to define a second accommodating space  125  and third accommodating space  135 . The second surface  123  and the third surface  133  are also respectively provided with multiple assembly holes and slots. In particular, each of the second surface  123  and third surface  133  respectively includes a first opening  121  and  131  at opposite positions, and a second opening  122  and  132  also located at opposite positions. 
         [0033]    When the entire structure is assembled, the first surface  111  is coupled to a patting actuator block  40  having an eccentric portion. The patting actuator block  40  comprises a driving motor  41 . The driving motor  41  has a driving end  411 , and a bottom coupled to a fixing frame  412 . After the driving motor  41  and its driving end  411  are assembled in the fixing frame  412 , the assembly of the fixing frame  412  and driving motor  41  are securely mounted on the first surface  111 , the axle of the driving motor  41  being parallel with the first surface  111 . Furthermore, a decelerator device  42  is disposed below the driving motor  41 . The decelerator device  42  includes a shaft  43  having one end portion mounted with a decelerator gear  42  that is coupled to the driving end  411  via a transmission belt. Each of the two distal ends of the shaft  43  is mounted through a bearing  45  used as support during operation. The shaft  43  extends on an outer side of each bearing  45  to form an eccentric portion  44 . Each of the two eccentric portions  44  is assembled with a coupling bearing  54  that is in turn connected with a multi-axes transmission shaft  541 . The position of the driving motor  41  is arranged above the position of the decelerator device  42  over the first surface  111 . An upper side of the second surface  124  of the second frame region  12  is coupled to a sliding actuator block  20  that includes a gear  24  at two lateral sides and is adapted to rotate on the toothed rail  60 . An upper side of the sliding actuator block  20  includes a decelerator device  22 . An interior of the decelerator device  22  includes the assembly of a rotary screwed shaft (not shown) with a rotary gear (not shown) adapted to transmit a rotation movement at an angle of 90 degrees. The decelerator device  22  also comprises a decelerator gear  23  at a position corresponding to the second surface  123  to cooperate with the rotary screwed shaft and couple to an end of a transmission shaft  25  at an angle of 90 degrees. Examples of the decelerator devices  22 / 33  are well-known in the prior art, such as those illustrated in U.S. Pat. No. 7,029,453 B2, the disclosure of which is incorporated herein by reference. One end portion of the transmission shaft  25  corresponding to the decelerator device  22  is assembled with a bearing  26 . In addition, each of two end portions of the transmission shaft  25  is also assembled with a gear  24  and a roller  27 . The bearing  26  is disposed above the surface  134  so as to support the transmission shaft  25 . The two distal ends of the transmission shaft  25  are secured through slots  126 / 136  provided on the second surface  124  and the third surface  134 , respectively. The decelerator device  22  is coupled to a driving motor  21  right below the second surface  124 . One end of the driving motor  21  corresponding to a decelerator gear  23  is assembled with a driving wheel  211  coupled to the decelerator gear  23  via a transmission belt. The decelerator gear  23  and the driving wheel  211 , once mounted on the second surface  124 , respectively extend out of the first opening  121  and second opening  122  of the second surface  123  to be received in the second accommodating space  125 . The third surface  134  of the third frame region  13  is assembled with a kneading actuator block  30  having an inclined eccentric portion. The placement of component parts for the kneading actuator block  30  is opposite to the placement of component parts for the sliding actuator block  20  on the second frame region. A driving motor  31  of the kneading actuator block  30  is disposed above the third surface  134 . One end of the driving motor  31  corresponding to the third surface  133  is coupled to a driving wheel  311  mounted on a decelerator device  32  (similar to the decelerator device  22 ) right below the third surface  134 . One end of the decelerator device  32  corresponding to the driving wheel  311  is assembled with a decelerator gear  33  coupled to the driving wheel  311  via a transmission belt. The driving wheel  311  and the decelerator gear  33 , once mounted on the third surface  134 , respectively extend out of the second opening  132  and the first opening  131  of the third surface  133  and second surface  124  to be received in the third accommodating space  135 . The decelerator device  32  is coupled to a transmission shaft  35  at an angle of 90 degrees. One end of the transmission shaft  35  corresponding to the decelerator device  32  is coupled to a bearing  36 . In addition, each of two end portions of the transmission shaft  35  is coupled to a roller  34 . The bearing  36  is disposed above the surface  124  so as to support the transmission shaft  35 . The two distal ends of the transmission shaft  35  are secured through slots  127 / 137  provided on the second surface  124  and the third surface  134 , respectively. 
         [0034]      FIGS. 4-6  are schematic views showing an assembled embodiment of the present invention. During operation, the gear  24  and roller  27  at each of the two ends of the sliding actuator block  20  are located in the toothed rail  60  on the back rest of the massage chair  80 . Each set of the gear  24  and roller  27  is driven by the driving parts of the sliding actuator block  20  through the gear  24  to cause a sliding movement in the toothed rail  60 . The transmission shaft  35  drives a movement of two swaying arms  51  of a massage device  50  that are respectively coupled to two connection regions of the transmission shaft  35  of the kneading actuator block  30 . Each connection region between the transmission shaft  35  and one swaying arm  51  is also provided with an inclined eccentric portion  511 , placed in a position facing each other. When the transmission shaft  35  rotates, the two inclined eccentric portions  511  are driven to generate inward and outward kneading movements. One end of each swaying arm  51  opposite the inclined eccentric portion  511  is also coupled to an arm  53  and a roller  531 . A back massage movement is provided by a combined action of the rolling movement of the roller  531  and the movement of the two swaying arms  51 . In addition, a multi-axes link  52  is coupled to a portion of each of the two swaying arms  51 . One side of the multi-axes link  52  corresponding to the assembly frame  10  includes a multi-axes link hole  521 . Each of the two eccentric portions  44  of the patting actuator block  40  is assembled with a coupling bearing  54  via a fastener nut  542 . One end of each coupling bearing  54  is mounted with a multi-axes transmission shaft  541 , and is further connected to the multi-axes link hole  521 . During rotation, the offset positions of the two eccentric portions  44  cause vibration of the coupling bearings  54 , which is transmitted via the transmission shaft  541  to the multi-axes link  52 . As a result, the swaying arms  51  are caused to push the rollers  531  forward, thereby creating kneading and patting movements. 
         [0035]      FIGS. 7-9  are various views showing an assembled massage device according to an embodiment of the present invention. The assembly of the massage chair based on the above-described configuration can provide the following advantages. First, the accommodating space provided by the assembly frame  10  can suitably receive each component part of the patting actuator block  40 , sliding actuator block  20  and kneading actuator block  30  in a reduced space. More particularly, the configuration of the assembly frame  10  allows a placement of the patting actuator block  40  in a transversal position in the first frame region  11 , whereas the sliding actuator block  20  and kneading actuator block  30  can be placed vertically over each other in the second frame region  12  and third frame region  13 . As the driving outputs of both the sliding actuator block  20  and kneading actuator block  30  are disposed in a stacked manner in the second accommodating space  125  and third accommodating space  135 , the relatively complex mechanical operation of the whole massage device can be performed in a reduced volume space without undesirable interferences. Furthermore, referring to  FIG. 10  which shows an assembled configuration of the present invention, all the massage actuating components in the back rest can be simultaneously assembled in a same device within a reduced space. As a result, the volume of the back rest of the massage chair  80  can be advantageously reduced. Second, in addition to the ability to mount all the massage actuating structures simultaneously instead of through multiple assembly operations during the manufacture, the design configuration of the present invention also allows simultaneous removal of the entire device structure for replacement during a repair operation. Because no cumbersome disassembly operations are required, the maintenance and repair operations can therefore be performed in an efficient manner. 
         [0036]    As described above, at least one advantage of the placement configuration provided by the present invention is the ability to reduce the assembly volume and facilitate the repair operations. 
         [0037]    Although the present invention has been described with reference to the preferred embodiment thereof, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the present invention which is intended to be defined by the appended claims.