The present invention relates tc portable backrests fcr use with chairs bees a c ether ^* —m_.t-_.re, vehicle seats and wheelchairs. Mere speci call , the invention relates to a portable backrest of this nature having a novel means

_> for adjusting its support contour Pa accommodate individual users with backs of various physical dimensions.

BACKGROUND OF TKS IWΞMTICN The field of backrests has been the subject of developmental efforts for many years. This is due largely to the fact that back pain and back disorders afflict a major segment of the population.

The human spinal column is normally formed with an elongated S-shape which may vary both as to configu ation and dimensions from one individual to another. For a number of reasons such as bad posture, poor sitting habits, or poor physical condition, the natural elongated S-shape of the spinal column may become distorted. When this occurs, abnormal concentrations of pressure occur on the vertebrae and the intervertebrai discs. This, in turn, causes pressure on the nerves in the spinal cord frequently resulting in severe back pain, neck pain, fatigue and headaches. A well constructed backrest, properly adjusted, tends to restore the spinal S-curve to proper con iguration and thereby relieves or avoids the uneven pressures which cause troublesome pain and fatigue. The following prior art patents disclose a variety of backrests, some .of which are portable and others of which are built into chairs or vehicle seats: 2,756,809 - Sndresen; 2,343,195 - Barvaeus 2,894,565 - Conner; 3,642,319 - Berchicci; 3,663,055 - Gale; 3,762,769 - Poschl; 3,990,742 - Glass et al.; and 4,350,338 - Weiner.

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SUMMARY 07 TH2 ISTZNTION

One object of the present invention is to provide a l mbcsacrai backrest having a back en aging contour which is adjustable and adapted to accommodate users' backs which vary widely in configuration and dimension.

Another object is to provide a backrest of the foregoing type which may be adjusted σuickly and easily while in position behind the user. Such adjustment may be effected manually or by power.

A further object is to provide a backrest with a contour defined by a regulator spindle inserted between a foundation frame and a resilient back support, the regulator spindle being adjustable along the back support and adapted to define a transverse plane of rigidity at the proper level to provide comfortable support for the individual user's back.

Another object is to provide a backrest of the character set forth above which includes appropriate power means for massaging the sacral lumbar region of the back.

Still another object of the invention is to provide a backrest of the character set forth above which will be of simple, rugged construction, economical to manufacture, and require little if any maintenance.

The foregoing is accomplished by use of a regulator spindle interposed between the foundation frame and the resilient bowed back support in front of same, the regulator spindle being rotatably adjustable longitudinally of the back support and thereby defining a transverse plane of rigidity across the back support at any selected position of adjustment. The regulator spindle may be adjusted either manually or by power means.

3RIΞF DESCRIPTION OF THZ DRAWINGS

Figure 1 is a perspective view of an illustrative portable backrest embodying the present invention, with the cover opened to show internal structure.

Fig. 1A is another perspective view of the adjustable backrest shown in Fig. 1 but with the outer cover and pad completely removed.

Fig. 2 is an enlarged sectional view taken axialiy of the regulator spindle in the plane of the line 2-2 in Fig. LA.

Figs. 3 and 4 are transverse sectional views taken in Fig. 2 through the regulator spindle and adjacent structure of the backrest in the planes of the lines 3-3 and 4-4, respectively.

Fig. 5 is an axial sectional view similar to Fig. 2 but illustrating a modified form of regulator spindle also embodying the invention.

Fig. 6 is a transverse sectional ^' view through the regulator spindle of Fig. 5, taken in the plane of the line β-β.

Fig. 7 is an axial sectional view similar to Fig. 5 but showing another modified form of regulator spindle also embodying the present invention.

Fig. 8 is a transverse sectional view through the regulator spindle of Fig. 7, taken in the plane of the line 8-8.

Fig. 9 is an axial sectional view similar to Fig. 7. but illustrating still another form of regulator spindle embodying the present invention.

Fig. 10 is a transverse sectional view through the regulator spindle shown in Fig. 9, taken in the plane of the line 10-10.

Fig. 11 is an enlarged fragmentary elevational view of a portion of the regulator spindle of Fig. 9, with certain related structure shown in transverse section.

Fig. 12 is a fragmentary plan view illustrating a modified

form of backrest also embodying the invention wherein the ^" regulator spindle is ^' adjusted by power means.

Figs. 13 and 14 are transverse sectional views through the regulator spindle shown in Fig. 12, taken in the planes of the lines 13-13 and 14-1 ^* 4, respectfully.

Fig. 15 is a diagrammatic view of a control circuit for the backrest adjusting means of Fig. 12 and shewing an enlarged elevational view of the control switch.

Fig. 16 is a fragmentary plan view of another form of backrest embodying the invention and utilizing a power driven regulator spindle.

Fig. 17 is an enlarged fragmentary longitudinal sectional view through the drive mechanism associated with the regulator spindle, taken in the plane of the line 17-17 in Fig. 16.

Fig. 17A is an enlarged fragmentary sectional view detailing the follower key and pin and their engagement with the dual threaded drive shaft.

Fig. 18 is a diagrammatic view of a control circuit for the backrest adjusting means of Fig. 16 and showing an enlarged elevational view of the control switch.

Fig. 19 is an enlarged fragmentary plan view, partly in section, illustrating still another form of backrest embodying the invention and having a power driven regulator spindle.

Fig. 20 is a transverse sectional view through the regulator spindle and associated rack shown in Fig. 19.

Fig. 21 is an enlarged fragmentary sectional view taken in the plane of the line 21-21 in Fig. 20.

Fig. 22 is a diagrammatic view illustrating the control circuit for the backrest adjusting means of Figs. 19 and 20 and showing the face of the three position control switch.

SAOORIGINAL

DETAILED DESCRIPTION OF THE E TIO Referring more specifically to Figures 1-4, the invention is there exem li ied in an illustrative l mbosacral backrest 30. The backrest 30 comprises an upstanding foundation frame 31 of generally rectangular form which may be fabricated from materials such as high strength plastic or a light metal stamping. The frame 31 happens to be formed with an out-turned peripheral margin 32 and suitable stiffening ribs (not shown). The backrest 30 includes a yieldable back support 34 of somewhat greater length than the foundation frame 31 but connected thereto at its ends to define a resilient bowed configuration. The back- support 34 comprises a series of laterally spaced bands 35 of spring steel or similar material. The upper end portions of the bands 35 are connected to the frame 31 by brackets 36 and the lower end portions are connected to the frame by brackets 38. The brackets 36 are spaced below the upper edge of the frame by an amount which is at least equal to the width of an individual band. This tends to create a moderate biasing force urging the bands 35 against the frame 31 and thus tending to shift the apex of their curvature to a point slightly below the horizontal center line of the frame. A contour adjusting means is interposed between the bowed spring bands 35 of the back support and the foundation frame 31 to adjust the contour of the back support longitudinally and transversely thereof.

The entire backrest 30 is enclosed within a cover 39 of upholstery fabric or other appropriate sheet material (Fig. 1). A resilient pad 40, of foam rubber or the like, is interposed between the outer faces of the back support bands 35 and the front panel 41 of the cover. The rear panel 42 of the cover encloses the rear face of the foundation frame 31 and may

g include straps for attaching the backrest to furr. some other- ixed-support. The cover 39 is secured in place over the backrest 30 by means of a double zipper 44 which traverses the two sides and top of the backrest cover. The zipper 44 has two sliders 45, 46 operable independently of each other to permit access to the contour adjusting means.

In accordance with one aspect of the present invention, provision is made for adjusting the contour of the yieldable back support 34 by means of a regulator spindle 48 and an associated pair of rack and pinion mechanisms 49. The regulator spindle 48 comprises a body 50 of circular cross- section and an axial section of double concave form. Thus, the body has a minimum diameter at its center, tapering gently outward to a larger diameter adjacent each of its ends. his disposes the yieldable support bands 35 in a slightly concave orientation longitudinally of the spindle 48 and thereby provides a transverse plane of rigidity across the back support 34.

The rack and pinion mechanisms 49 are located with one adjacent each end of the adjusting spindle 48 (Figs. 2-4). Each such mechanism comprises a rack 51 fixed upon or integrally molded with the foundation frame 31 and having a series of longitudinally spaced tooth recesses 52. Each rack 51 is spaced inwardly from the ou turned side margin 32 of the foundation frame 31. The mechanism 49 also includes a pinion 54 having a plurality of teeth 55 adapted to mesh with the tooth recesses 52 in the rack. While the teeth 54 in this instance project slightly above the peripheral surface of the spindle 4 ^* 8, the user of the backrest 30 is not subjected to discomfort or annoyance because the foam rubber pad 40 covers the teeth and provides adequate cushioning to preclude any problem of interference with the use of the backrest.

In order to permit manual adjustment of the spindle 43 longitudinally of the back support 34 a d its resilient bands 35, the ends of the spindle are extended slightly beyond the margins 32 of the frame 31 and provided with knurled adjusting knobs 56. To preclude interference with the outer cover 39, the sides of the frame 31 and their marginal edges 32 are indented slightly in the region of adjusting movement of the spindle 48. The overall length of the spindle, including the adjusting knobs 56, is accordingly limited to approximately the width of the non-indented portion of the sides of the frame 31. 3y reason of the foregoing construction, it will be appreciated that the adjusting spindle 43 may be rotatably adjusted into any selected one of a plurality of predetermined positions throughout its range of rotational movement. Each position of adjustment thus defines a transverse plane of rigidity across the back support at such selected position and thereby effects an adjustment in the contour of the back support.

To guard against an unintentional change in the position of adjustment of the spindle 48 due to movements of the user pressing against the back support 34, provision is made for locking the -spindle 48 in a given position of adjustment until manually shifted to another position by the deliberate act of the user. This is accomplished by forming the pinion 54 as a polygon, in this instance a hexagon, with each tooth situated in one side of the polygon. Thus, when a tooth is engaged in a tooth recess of the rack, the polygon side associated with that tooth constitutes a locking face 56 which abuts solidly against the face of the rack 51. Due to the pressure applied by the outwardly bowed support bands 35

BADORIGINAL

urging the spindle 48 against tne racks 51, the spindle remains locked in position until sufficient torque is applied to the spindle 48 by the user to overcome the spring pressure of the overlying support bands 35.

In order to avoid inadvertent disengagement of the spindle 48 from the racks 51 as the spindle approaches each extreme of its rotational adjustment, a pair of stop abutments 53 is mounted at each end of at least one rack (Fig. 3). The abutments 58 are so proportioned that they will engage the spindle 48 diametrically when in the encmost positions along the rack 51.

Turning next to Figs. 5 and 6, there is shown a modified form of regulator spindle 59 also embodying the present invention. The spindle 59 is closely similar to the regulator spindle 48 shown in Figs..1-4, the principal difference being that the pinion 60 of spindle 59 is smaller in diameter than that of spindle 48. The difference in diameter is sufficient to prevent the points of the teeth 61 of pinion 60 from projecting above the peripheral surface of the spindle 59.

Accidental movement of the spindle 59 out of a given position of adjustment is precluded by making each pinion 60 of polygonal cross-section, similar to the pinion 54 of spindle 48, with a flat locking face 62 adjacent each tooth 61. When a tooth 61 is engaged with a tooth recess in rack 64, the locking face 62 abuts against the opposed face of the rack until the user applies enough torque to overcome the frictional effect of the support bands 35. Movement of the spindle 59 beyond its associated racks 64 is precluded by stop abutments 65 at the ends of at least one rack.

Figs. 7 and 8 illustrate another modified form of regulator spindle 68 embodying the present invention. The spindle 68

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is closely similar to the spindle 59 described above. In- this instance, ^* however, the ^' inions 69 and the r associated racks 70 are situated closer together along the axis of spindle 63, being located between an outermost band 35 and a next outermost band 35. The pinion teeth 72 do not project above the outer peripheral surface of the spindle 68. Locking faces 71 surrounding the respective teeth 72 serve to maintain the spindle 68 in a selected position of adjustment. At least one of the racks 70 has stop abutt ents at its longitudinal extremities.

Figs 9-11 show still another modified form of regulator spindle 74 which also embodies the present invention. In this case, the regulator spindle 74 is fashioned with a pair of pinions 75 each having generally cylinderical teeth 76. The pinion 75 is of polygonal cross-section, defining a locking face 78 surrounding each tooth 76 similar to those described earlier herein. The rack for each pinion is defined by an overlying one of resilient back support bands 35A which has a series of longitudinally spaced holes 77 adapted for engagement by the pinion teeth 76. The latter have a height only slightly greater than the thickness of the Bands 35A. Instead of racks,- the foundation frame 31 is formed with a pair of laterally spaced upstanding ribs 79 running lengthwise of the frame 31. The ribs 79 are disposed in alignment with the pinions 75 and each rib is formed with a longitudinal guideway 80 adapted to accommodate the pinion teeth 76. As indicated in Fig. 11, there is ample clearance between the guideway 80 and the pinion teeth 76. The spindle 74 is provided with adjusting knobs 57 and may be adjusted manually in the same manner as the spindles 48, 59 and 68. Stop abutments 81 may be situated at 'each end of one ^' of the ribs 79 to prevent the spindle 74 from overtraveling.

L

Referring new to Figs..12-13, there is shewn a backrest 32 similar to the backrest 30 described above and also embodying the present invention. In this instance, the backrest 32 has a power driven regulator spindle 34 for adjusting the contour of the yieldable back support 34. Except for certain modifications which will be noted herein, the general configuration of the spindle 84 is closely similar to that of the regulator spindles 48, 59, 68, and 74 described earlier herein. Instead of a rack and pinion connection with the foundation plate 31, the spindle 34 is formed with an annular wheel flange 85 adjacent each end thereof. Each wheel flange 85 is adapted to roll longitudinally along a guideway 86 formed in an upstanding rib 88 integral with, or fixed to, the foundation frame 31. The peripheral areas of the spindle 84 on either side of each wheel flange also roll on the upper faces of the ribs 38. The resilient bands 35 of the yieldable support member 34 bear against the peripheral surface of the regulator spindle 84. This maintains engagement between the wheel flanges 85 and guideways 86, and between the adjacent peripheral areas of the spindle 84 and the top surfaces of the ribs 88. Stop abutments 39, 90 are situated at the ends of the respective guideways 86 and ribs 88 to prevent overtravel of the spindle 84.

Provision is made in the backrest 82 for moving the regulator spindle 84 into any selected position within its range of rotational adjustment between the stops 89, 90. As in the case of the regulator spindles previously described, this provides a transverse plane of rigidity across the back support at the selected position and thereby adjusts the contour of the back support to accommodate -the back of the individual user. In furtherance of such objective, ^** a reversible

electric motor 91, including a reduction gear 92, is secured to the foundation frame 31, In this- instance, the motor and ^** reduction gear housing may be mounted so as to project a slight amount through the main panei area of the foundation frame 31, thus providing the necessary clearance with the resilient support bands 35. Output shaft 94 of the reduction gear extends from the latter through a bearing 95 fixed to the frame 31 and terminates in a bevel pinion 96. The latter drivingl .meshes with a pinion 98 fixed to worm shaft 99 extending transversely of the spindle 34. The worm shaft 99 is journalled for rotation in a pair of bearings 1Q0, 101 fixed to the frame 31. In order to receive power from the worm shaft 99, the spindle 84 is formed with a centrally mounted worm wheel 102 which drivingly meshes with the shaft 99. Since a worm wheel drive is inherently sel -locking, no additional locking means need be provided to constrain the spindle 34 against movement when in a selected position of adjustment.

Operation of the motor driven adjustment means for the spindle 84 will become more apparent from the diagram of the control system in Fig. 15. Accordingly, it will be noted that the motor 91 is connected to a conventional motor controller 104 which is powered from an external power source indicated by the letter , Control switch 105, which is mounted on the lower right-hand side of the backrest 32 is connected directly to the motor controller 104. Upper limit switch 106, mounted on abutment 89, and lower limit switch 108, mounted on abutment 90, are each connected to the motor controller 104. With the spindle 84 in the position shown in Fig. 12, shifting the slider of switch 105 to the "UP" position will cause the motor to drive the spindle 84 upwardly. Release of the slider back to neutral position will cause the spindle to

stop in the selected position. In the event, however, that the slider of switch 105 ^" should ^" be held in the "; ^■ ?" position long enough to drive the spindle 34 against the upper stop abutments 39, the upper limit switch 106 becomes actuated to de-energize the motor 91. At that point, the only operative position of the switch 105 will be the "DOWN" position. Conversely, if the spindle 84 should be driven down to the lower stop abutments 90 so as to actuate the lower limit switch 108, power to drive the motor* 91 downwardly will be cut off and the only operative position of the switch 105 will be the "UP" position.

With the motor 91 de-energized, it would be possible to adjust the position of the regulator spindle 34 manually by turning either or both adjusting knobs 57. With sufficient torque applied manually to overcome the friction produced by overlying bands 35, the. worm wheel will readily roll along the worm shaft 90 and remain engaged therewith.

Turning next to Figs. 16-18, another aspect of the present invention is there shown in an illustrative backrest 110. The latter is closely similar to the backrest 82 described above from the standpoint of the foundation frame 31, the back support member 34 defined by resilient bands 35, and a regulator spindle 111 identical to the spindle 84 except for elimination of the worm wheel 102. The backrest 110 differs from the backrest 82 in that the primary purpose of the backrest 110 is to serve as a power driven device for massaging the sacral lumbar region of the back.

In furtherance of the foregoing objective, the backrest 110 is equipped with a unidirectional motor 112, including a reduction gear 114, mounted on the foundation frame 31 in- - - • the same manner as the motor 91 referred to above. The

reduction gear 114 has an output shaft 115 wnicn passes through a fixed bearing 116 on the frame 31 and terminates in a bevel pinion 113. The latter drivingly meshes with a bevel pinion on the end of a dual threaded shaft 120 extending along the center line of the frame 31. The shaft 120 is journalled in fixed bearings 121, 122 attached to the frame 31 and passes transversely under the regulator spindle 111. A follower 124 is slideably mounted upon the shaft 120 and driven axially thereof by the latter. The follower is formed with a pair of upstanding arms 125 which straddle the central portion of the regulator spindle 111 and transmit power thereto from the shaft 120.

The dual threaded shaft 120 is adapted to reciprocate the follower 124 between the bearings 121, 122 as the shaft 120 rotates unidirectionally. To do this, the shaft 120 is formed with two intersecting threads of opposite hand but equal pitch (Fig. 17). The threads are connected at or near each end of the shaft 120. A follower key 126 in the form of a short screw with a projecting pin 128 at its lower end is threadedly engaged in a tapped bore 129 in the upper central portion of the follower (Figs. 17, 17A) . The pin 123 is of appropriate lengt -and diameter to engage either one of the dual threads 130, 131 of the shaft 120.

Assuming that the shaft 120 is turning in a clockwise direction, when viewed from the end of pinion 119, and that the pin 128 of the follower key is engaged with the thread 130, the follower 124 will be driven toward the pinion end of the shaft 120. When the follower 124 reaches the end of the thread 130, with the shaft still rotating clockwise, the pin 128 will cross over from the thread 130 to the thread 131 via the connecting shunt 132. With the shaft 120 still rotating in a clockwise direction, the follower pin 128 will

enter the thread 131, reversing the follower 124 and driving it toward the bearing 122. When the follower pin 123 reaches the end of the thread 131, it crosses over to the thread 13C via shunt 134, reversing the follower 124 and driving it toward the bearing 121.

Fig. 18 is a diagramatic view of the control system of backrest 110. The motor 112 is connected to conventional motor controller 135 which is energized from an external power

^* *> source "V. On-off switch 136, mounted on the lower right- hand side of the backrest 110, is connected directly to the controller 135. With the switch in the "ON" position, the regulator spindle 111 will be reciprocated between the bearings 121 122, changing the contour of the support member 34 in a timed cycle appropriate for lower back massage. Since the spindle 111 remains positively connected to its mechanical drive and the reversals in its direction of movement are effected by the mechanical drive, no stops are needed at the ends of the ribs 88.

Figs 19-22 depict still another power adjusted backrest 138 also embodying the present invention. The basic structure of the backrest 128 is similar to that of the backrests 82 and 110 described above. The differences reside primarily in the construction of the regulator spindle 139 and the related guide structure on the foundation frame 31.

The regulator spindle 139 is similar in general shape to the spindles 84 and 111 previously described. Its longitudinal cross- section has a double concave shape for cooperation with the resilient bands 35 of the back support 34. The spindle 139 is supported and guided throughout its range of rotational adjustment by means of a rack 140 spaced inwardly from the left side margin of the frame 31, and an upstanding rib 141 spaced inwardly from the right side margin of the frame (as viewed in Fig. 19). The

BAD-OlnJGJWAu ^" /"

right-hand end portion or the spindle 139 is formed with a pair of flanges 142 which straddle the rib 141 and maintain engagement between the latter and the spindle.

The left-hand end portion of the spindle 139 teiescopicaily receives a drive motor 144 and reduction gear 145. The common housing of the motor and reduction gear 144, 145 is fixed to a sliding base 146 as by means of brackets 147 and is thereby res-trained against rotation. The base 146 straddles the rack 140 and is adapted for reciprocating movement therealong (Figs. 19- 21). The inner end of the housing of motor 144 has a fixed boss

148 extending axially therefrom. ^* The boss 148 carries a bearing

149 recessed in the spindle 139 and which supports the left-hand end portion of the latter for rotation about the housing of the motor and reduction gear 144, 145. The reduction gear has an output shaft 150 carrying a drive pinion 151 which meshes with the rack 140. Power from an outside source is supplied to the motor 144 via a coiled elastic lead 152.

Since the motor 144 is reversible, it is adapted to traverse the spindle 139 in either direction longitudinally of the rack 140 and the rib 141. In the course of such action, the body of the spindle 139 is rotated as the motor 144, reduction gear 145 and sliding base 146 are reciprocated along the rack 140. In order to reduce frictional drag and wear between these members, the sliding base 146 is fashioned with rollers 143, in this case arranged in two pairs adjacent opposite ends of the base 146. The rollers 143 straddle the rack 140 and ride upon a pair of integral shoulders 143A extending the full length of the rack (Fig. 20, 21). To preclude overtravel, upper and lower stop abutments 152, 154 are fixed to the ends of the rib 141 and the rack 140. In addition, upper and lower limit switches 155, 156 are fixed to the respective stop abutments 152, 154 on the rack 14

RIGINAL

The operation of the power adjustment means associated with the regulator spindle 139 will be better understood upon reference to the diagram of the control system in Fig. 22. ^* The reversible motor 144, nested within one end of the spindle 139, is connected via a coiled resilient lead 152 to conventional motor controller 158. The latter is powered from an external source designated by the letter "V". A three-way control switch 159, mounted on the lower right-hand side of the backrest 138, is connected to the mαtor controller 153 by two separate lines. Coper limit switch 155, located at the upper end of the rack, and lower limit switch 156, at the lower end of the rack, are each connected to the mαtor controller 158. With the spindle 139 in the position shown in Fig. 19, shifting the operating lever of switch 159 to the "UP" position will cause the motor 144 to drive the spindle upwardly. Release of the operating lever to the middle or neutral position will cause the spindle to stop in any selected position. Shifting the operating lever of the switch 159 to the "DOWN ¹ ' position will cause the motor 144 to drive the spindle 139 downwardly, while return of the operating lever to neutral position will cause the spindle to stop. As in the case of the control system for the spindle 84 shown in Fig. 15, holding the operating lever in the "UP" position until the upper limit switch 155 is actuated by the sliding base 146 will de-energize ^" the motor 144. It then becomes necessary to move the operating lever to the "DOWN" position which will result in moving the spindle 139 downwardly. In like manner, if the downward movement is continued until the lower limit switch 156 is actuated, the motor will be de-energized and it will be necessary to shift the lever to the "UP" position to move the spindle upwardly.

In addition to the motions described in the previous para¬ graph, the operating lever of the control switch 159 has an

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"AUTO" position, the function of which is to drive the regulator spindle 139 upwardly and downwardly in a timed cycle. This cause the contour of the back support bands 33 to go through the necessary cyclic changes in contour to perform a lower back massage. The foregoing arrangement thus achieves the dual purpos of power adjustment of the regulator spindle 139 to any given position within its operating range, and automatic reciprocation of the spindle in a timed cycle through its operating range for back massage.

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