FIELD OF THE INVENTION

[0001] The application relates to a recliner chair with a backrest pivot lin kage that allows the backrest to pivot between an upright position and a reclining position.

BACKGROUND

[0002] A typical recliner chair 10 as shown on FIG . 1, includes a chassis 12 that supports a seat 14, a backrest 16, and a leg rest 18 by way of a reclining carriage 20. An example of a typical reclining carriage 20 is shown in detail in FIGS. 2A-2C. As illustrated in FIG. 1, the reclining carriage 20 allows the backrest 16, the seat 14, and the leg rest 18, to shift between an upright position shown in solid lines, an extended position shown in first dashed lines, and a reclining position shown in second dashed lines. I n the upright position, the backrest 16 is tilted in a generally u pright orientation, the seat 14 is in a generally horizontal position, and the leg rest 18 is retracted in a generally downward position . In the extended position, the seat 14 and backrest 16 are translated forward with respect to the chassis 12 but remain in the generally upright and generally horizontal positions, respectively, while the leg rest 18 is extended and pivoted upward ly to a generally horizontal position . In the reclining position, the backrest is tiled rearward and downwardly into a reclining horizontal position, while the seat 14 and the leg rest 18 are both translated forward and remain in their respective generally horizontal positions.

[0003] The reclining carriage 20 is an example of a zero wall reclining carriage in which the recliner chair 10 may be shifted between the upright position and the reclining position even when a rear side of the backrest 16 is disposed against a wall when the chair is in the upright position . In other words, the recliner chair 10 can recline with zero clearance distance between the backrest 16 and a wall. This is possible because of the forward translation of the seat 14 and the backrest 16 on the reclining carriage 20 when shifting from the upright position to the reclining position . [0004] Turning now to FIGS. 2A, 2B, and 2C, the reclining carriage 20 is shown in detail in the upright position (FIG. 2A), the extended position (FIG. 2B), and the reclining position (FIG. 2C). The reclining carriage 20 includes a side hardware 22 for securing to the chassis 12, a seat box 24 supported by the side hardware 22, a backrest pivot linkage 26 for supporting and pivoting the backrest 16, and a leg rest linkage 28 for supporting and pivoting the leg rest 18. The side hardware 22 includes a chassis bracket 30 that is fixedly secured to the chassis 12. A pair of seat box support links 32 are pivotably connected to each of the side hardware 22 and the seat box 24 so as to shiftably support the seat box 24 from the side hardware 22. A backrest support bracket 34 is fixedly mounted to the back end of the seat box 24. The backrest pivot linkage 26 includes a back post 36 that is pivotably connected to the backrest support bracket 34 at a pivot 38 and supports the backrest 16. The backrest pivot linkage 26 also includes a first link 40 pivotably connected to the back post 36, a second link 42 pivotably connected to the first link 40, and a third link 44 pivotably connected to each of the second link 42 and to the side hardware 22.

[0005] As best seen with reference to FIGS. 2B and 2C, when the backrest 16 is shifted between its upright position and the reclining position, the back post 36 pivots around the pivot 38. Further, the pivot 38 does not shift, i.e. is fixed, in relation to the seat box 24. Thus, even though the seat box 24 is moving forward and/or backward on the side hardware 22 when shifting between the extended position and the reclining position, the pivot 38 of the backrest 16 is fixed relative to the seat 14. The back post 36 has an L-shape to align the front surface of the backrest 16 with the back edge of the seat 14. The L-shape offsets the axis of the backrest 16 radially from the pivot 38 such that the axis of the backrest 16 is not radially aligned through the pivot 38 . In this arrangement, as can be seen in FIG. 2C, when the backrest pivots to the reclining position, the lower end, or lumbar region 46, of the backrest 16 separates away from the back edge of the seat 14. This shifting of the lumbar region 46 relative to the seat 14 can be uncomfortable for a person sitting in the recliner chair and may cause the person to re-adjust his or her body after the seat 14 and the backrest 16 have been shifted to the reclining position. Further, the shifting of the lumbar region 46 can cause additional discomfort to the seated person when the backrest 16 is pivoted upwardly from the reclining position back into the extended position.

SUMMARY

[0006] According to some aspects of the present disclosure, a recliner chair has a backrest pivot linkage arranged to reduce or eliminate shifting of a lumbar support area on a backrest relative to the lumbar area of a person seated in the recliner chair as the backrest rotates between an upright position and a reclining position.

[0007] In one exemplary arrangement, the recliner chair has a backrest rotatably coupled to a seat by a backrest pivot linkage that allows the backrest to pivot relative to the seat about first and second pivot points between an upright position and a reclining position, wherein the first and second pivot points move relative to the seat as the backrest pivots between the upright position and the reclining position.

[0008] In another exemplary arrangement, a reclining carriage for a recliner chair includes a chassis bracket, a seat box for supporting a seat, and a backrest pivot linkage to rotatably support a backrest. The backrest pivot linkage includes a back post for operatively securing to the back rest, a first recliner link, and a second recliner link. The first recliner link is pivotably connected to the back post at a first pivot and pivotably connected to the seat box at a third pivot. The second recliner link is pivotably connected to the back post at a second pivot and pivotably connected to the seat box at a fourth pivot. The first and second pivots shift toward the seat box when the back post rotates from an upright position to a reclining position.

[0009] In further accordance with any one or more of the foregoing aspects and exemplary arrangements, a recliner chair, reclining carriage, and/or backrest pivot linkage according to the teachings of the present disclosure may include any one or more of the following optional forms.

[0010] In some optional forms, the first and second pivots move toward the seat as the backrest rotates from an upright position to a reclining position and the first and second pivots move away from the seat as the backrest rotates from the reclining position to the upright position. [0011] In some optional forms, the backrest pivot linkage is part of a recliner carriage. The reclining carriage may cause the seat to shift in translation as the backrest shifts between the upright position and the reclining position. The reclining carriage may be a tri-recliner linkage that shifts the backrest between an upright or sitting position, an extended or TV position, and a reclining position. Preferably, the reclining carriage is also or alternatively a zero wall reclining carriage. The first and second pivots preferably move in the same direction as the seat when the backrest is shifted between the intermediate position and the reclined position.

[0012] In some optional forms, the reclining carriage includes a leg rest linkage, such as for supporting a leg rest at a front end of the seat box, that shifts a leg rest between a retracted position when the reclining carriage is in the upright position and an extended position. The leg rest linkage is preferably operatively connected with the chassis bracket and the seat box to rotate the leg rest between the retracted position adjacent the seat box and an extended position spaced from the seat box. Preferably, the reclining carriage shifts the leg rest between the retracted position and the extended position as the reclining carriage shifts between the upright position and an intermediate position between the upright position and the reclining position.

[0013] In some optional forms, the backrest pivot linkage includes a third recliner link pivotably connected to the first recliner link at a fifth pivot and pivotably connected to the chassis bracket at a sixth pivot. The first recliner link may include a first arm extending between the first pivot and the third pivot and a second arm extending between the third pivot and the fifth pivot. The second arm may be disposed at an angle relative to the first arm.

[0014] In some optional forms, the seat box is shiftably connected to the chassis bracket, wherein the seat box translates forward relative to the chassis bracket as the back post rotates from the upright position to the reclining position. The seat box may rotate relative to the chassis bracket as the back post rotates from the upright position to the reclining position. The seat box may be made of a single member or may be formed of multiple members. The seat box may include a seat beam to which the seat may be secured and a backrest support bracket carried by the seat beam. The backrest support bracket may be in a fixed position relative to the seat beam. Each of the first and second recliner links may be pivotably connected to the backrest support bracket.

[0015] Other viable aspects and optional forms of the recliner chair, reclining carriage, and backrest pivot linkage disclosed herein will be apparent upon consideration of the following detailed description and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a diagramatic side view of a recliner chair of the prior art;

[0017] FIGS 2A, 2B, and 2C are side elevational views of a reclining carriage according to the prior art in an upright position, an extended position, and a reclining position, respectively;

[0018] FIG. 3 is a partially exploded isometric view of a reclining carriage for use in a reclining chair according to the teachings of the present disclosure;

[0019] FIG. 4A is a side elevational view of a recliner chair with the reclining carriage of FIG. 3 in an upright position;

[0020] FIG. 4B is a side elevational view of the recliner chair of FIG. 4A with the recliner carriage in an extended position; and

[0021] FIG. 4C is a side elevational view of the recliner chair of FIG. 4A with the reclining carriage in a reclining position.

DETAILED DESCRIPTION

[0022] Turning now to the drawings, FIGS. 3-4B illustrate a reclining chair 50 and a reclining carriage 52 in one exemplary arrangement in accordance with the teachings of the present disclosure. Similar to the prior art, the recliner chair 50 also includes a chassis 12, a backrest 16, a seat 14, and a leg rest 18. Unlike the prior art however, the recliner chair includes the new reclining carriage 52, which supports the backrest 16, the seat 14, and the leg rest 18. The reclining carriage 52 may be secured directly to the chassis 12 and/or may be supported by a pedestal (not shown) separate from the chassis. In the present exemplary arrangement, the reclining carriage 52 is secured directly to the chassis 12 for support over a floor (not shown). Although only a single reclining carriage 52 is illustrated in the drawings, it is understood in the art that the recliner chair 50 preferably includes two such reclining carriages 52, one disposed on each of the left side and right side of the seat 14 and backrest 16, and each being the mirror image of the other and connected to each other by one or more brackets, struts, or other tying mechanisms so as to operate simultaneously and in tandem during operation of the recliner chair 50. Unlike the prior art, where the backrest 16 rotates relative to the seat 14 about a single pivot point that is fixed relative to the seat 14, in the recliner chair 50, the backrest 16 is rotatably connected with the seat 14 by a backrest pivot linkage 54, which is a part of the reclining carriage 52, that allows the backrest 16 to rotate relative to the seat 14 about a first pivot 56 and a second pivot 58 between the upright position as shown in FIG. 4A and the reclining position as shown in FIG. 4C. Further differentiating from the prior art, the first and second pivots 56 and 58 move relative to the seat 14 as the backrest 16 rotates between the upright position and the reclining position. In this arrangement, the recliner chair 50 causes the lumbar region 46 of the backrest 16 to remain engaged without substantial movement or shifting against a person's lumbar region of the back as the backrest 16 and seat 14 shift between the upright position and the reclining position.

[0023] As best seen in FIG. 3, the reclining carriage 52 includes the backrest pivot linkage 54, a seat box 60, side hardware including a chassis bracket 62 and seat box support links 64a and 64b, and a leg rest linkage 66. The reclining carriage 52 is a tri-recliner linkage that shifts the backrest between an upright or sitting position, an extended or TV position, and a reclining position, as is understood in the art. The reclining carriage 52 is also a zero wall reclining carriage that shifts forward away from a wall when shifting from the upright position to the reclining position as is understood in the art. However, the backrest pivot linkage 54 may be used on other types of recliner carriages that do not, for example, have zero wall movement or tri-recliner movement.

[0024] The seat box 60 is arranged to support the seat 14, either directly or indirectly. The seat box 60 includes a seat beam 68 arranged to be secured to the seat 14 and a backrest support bracket 70 disposed near a back end of the seat beam 68. The seat beam 68 and the backrest support bracket 70 may be formed integrally of a single piece of material, or may be formed separately for ease of manufacture and subsequently secured to each other by suitable fasteners such as screws or bolts, welding, or chemical fastener.

[0025] The chassis bracket 62 is adapted to be secured in a fixed position relative to the floor and/or the chassis 12, for example, by being secured to the chassis 12 with fasteners, such as screws or bolts, as shown in the drawings, or by being supported by a pedestal (not shown), or by another suitable support mechanism. In some arrangements, the reclining carriage 52 may be supported in such a way that the chassis bracket 62 can move relative to the chassis 12.

[0026] The seat box support link 64a has a first end pivotably secured to a rear portion of the seat beam 68 and a second end operatively supported by the chassis bracket 62 through one or more pivotable links of the side hardware. Similarly, the seat box support link 64b has a first end pivotably connected to a front end of the seat beam 68 and a second end operatively connected through one or more pivotable links toward the front end of the side hardware to the chassis bracket 62. The seat box support links 64a and 64b shiftably support the seat box 60 in a manner that allows the seat box 60 to translate forward and rearward relative to the chassis bracket 62. The seat box support links 64a, 64b also support the seat box 60 in a manner that causes the seat box 60 to rotate relative to the chassis bracket 62.

[0027] The leg rest linkage 66 supports the leg rest 18 on a leg rest bracket 72 and one or more links 74 operatively connected and arranged with the chassis bracket 62 and the side hardware and the seat box 60 so as to rotate the leg rest 18 between the retracted position adjacent to seat box 60 as shown in FIG. 4A and the extended position spaced from the seat box 60 as shown in FIGS. 4B and 4C.

[0028] The leg rest linkage 66 and the side hardware are arranged in a manner known in the art and the details of which are not the subject of the present disclosure. Therefore, further detailed explanation of these portions of the reclining carriage 52 is omitted for the sake of brevity and clarity, it being understood that a person of ordinary skill knows how to make and use these components without further elaboration. [0029] The backrest pivot linkage 54 includes a back post 76, a first recliner link 78, a second recliner link 80, and a third recliner link 82. The back post 76 is in the form of an elongate bar- shaped bracket having a first end 76a that is secured to the backrest 16, for example by being received within a grooved track and/or with fasteners, and a second end 76b. The first recliner link 78 is in the form of an L-shaped bar having a first arm 78a and a second arm 78b. The first arm 78a is angularly offset from the second arm 78b, for example at an angle of approximately 90 degrees. Each of the second recliner link 80 and the third recliner link 82 is in the form of a substantially straight bar having opposite first and second ends. The back post 76 is pivotably connected to the first recliner link 78 at the first pivot 56. The first pivot 56 is disposed along the back post 76 between the first end 76a and the second end 76b in an intermediate portion or area of the back post and is located at a distal end of the first arm 78a. The pivot 56 is formed, for example, by a pin (not shown) extending through aligned apertures 56a at the intermediate area of the back post 76 and aperture 56b at the distal end of the first arm 78a of the first recliner link 78. Preferably, each of the pivots described herein is, for example, formed by a pin that extends through aligned apertures. Of course, other pivot mechanisms suitable for pivotably connecting the various links and other components of the reclining carriage 52 may also or alternatively be used. The first recliner link 78 is pivotably connected to the seat box 60 at a third pivot 84. The third pivot 84 is disposed at the back end of the backrest support bracket 70 and at the intermediate angle of the first recliner link 78, for example, by a pin extending through aligned apertures 84a and 84b through the back end of the backrest support bracket 70 and the intermediate angle of the first recliner link 78, respectively. The second recliner link 80 has a first end that is pivotably connected to the second end 76b of the back post 76 at the second pivot 58, for example, by a pin extending through aligned apertures 58a and 58b. The second recliner link 80 has a second end pivotably connected to the seat box 56 at a fourth pivot 86, for example, formed by a pin extending through aligned apertures 86a in the backrest support bracket 70 and aperture 86b through the second end of the second recliner link 80. The backrest pivot linkage 54 as described to this point including the first through fourth pivots 56, 58, 84, and 86, is sufficient to cause the backrest 16 to rotate such that the lumbar region 46 will remain in improved contact with a person's lumbar region along substantially the entire range of motion of the backrest 16 and the seat 14 when shifting between the upright position and the reclining position. However, to provide additional control and tie-in of the rotation of the backrest 16 with the movement of the seat 14 and the leg rest 18, which is particu larly useful in a zero wall reclining carriage, preferably the first recliner link 78 is also operatively connected to the chassis bracket 62 by means of the third recliner link 82. Thus, a first end of the third recliner link 82 is pivotably connected to the second arm 78b of the first recliner link 78 at a fifth pivot 88 which, for example, includes a pin extending through aligned apertures 88a th rough a distal end of the second arm 78b and an apertu re 88b th rough the first end of the third recliner link 82. The second end of the third recliner lin k 82 is pivotably connected with the chassis bracket 62 at a sixth pivot 90, which for example, is formed by a pin extending through aligned apertures 90a th rough a back end of the chassis bracket 62 and another aperture (not visible) through the second end of the third recliner link 82.

[0030] With reference to FIGS. 4A-4C, the reclining movement of the recliner chair 50 and the reclining carriage 52 is described in fu rther detail. In moving from the upright position of FIG. 4A to the extended position of FIG. 4B, the third recliner link 82 and the seat box support links 64a and 64b pivot as shown, respectively, by arrows A, B, and C in FIG. 4A to move the seat 14 in translation forward and downward ly and also to rotate the seat 14 slightly in a

counterclockwise direction as viewed in the figures. Simu ltaneously, the leg rest linkage 62 rotates and extends the leg rest 18 outwardly or in a forward direction as shown by the arrow D in FIG. 4A until the reclining carriage 52 is in the extended position shown in FIG. 4B. As the reclining carriage 52 shifts from the upright position to the extended position, the backrest 16 and the backrest pivot linkage 54 remain substantially fixed in relation to the seat box 60. The reclining carriage 52 is preferably arranged in a manor understood in the art to have an equilibrium position shown at FIG. 4B in order to comfortably maintain the reclining chair in this position without requiring continual adjustment or locking of the reclining carriage. This position is commonly referred to as a TV position a nd it is often considered a preferred position for watching television and the like. From the extended position shown in FIG. 4B, the reclining carriage 52 may be either retu rned to the u pright position of FIG. 4A by reversing the travel of the reclining carriage 52 or the reclining carriage 52 can shift further into the reclining position shown in FIG. 4C.

[0031] As the reclining carriage 52 shifts from the extended position to the reclining position, the backrest pivot linkage 54 rotates the backrest 16 downwardly as shown by the arrow E in FIG. 4B while simultaneously translating the seat box 60 and the seat 14 forward and upwardly as shown by arrow F. The translation F of the seat box 60 rotates the first recliner link 78 in a clockwise direction as shown by arrow G about the third pivot 84 and also about the fifth pivot 88. This movement of the first recliner link 78 causes the back post 76 to simultaneously rotate in the counterclockwise direction E about the first pivot 56 and to cause the second recliner link 80 to rotate in a clockwise direction as shown by arrow H about the fourth pivot 84. Thus, as the backrest 16 and the back post 76 rotate in the counterclockwise direction E into the reclining position, the back post 76 pivots about each of the first pivot 56 and the second pivot 58 which simultaneously shift forward toward the seat box 60 and the seat 14. In this manner, the lumbar region 46 of the backrest 16 remains in a nearly constant radial position from the top back corner of the seat 14 rather than separating away from the seat 14 as occurs in the recliner chair 10 of the prior art.

[0032] To shift the reclining chair 50 from the reclining position to the extended position, the motions described above are reversed.

[0033] In a preferred arrangement, movement of the reclining carriage 52 between the upright, extended, and reclining positions is actuated with an electric drive, such as a motor and one or more drive mechanisms. Alternatively, the reclining carriage 52 may be shifted by manual mechanisms by the user. Such drive mechanism, whether manual or electric, or otherwise, are well understood in the art and not described in further detail herein for the sake of brevity.

[0034] Although the reclining carriage 52 as exemplified is in the form of zero or near zero wall reclining carriage, the backrest pivot linkage 54 may in other arrangements be used in a reclining carriage that is not a zero wall carriage. In such an arrangement, for example, rotation of the backrest 16 and the back post 76 may be driven, for example, by the backward pressure of a user against the backrest 16 and/or a drive mechanism operatively engaged with the second arm 78b of the first recliner link 78 to rotate the first recliner link 78 in the clockwise direction around the third pivot 84. Regardless of the mechanism for driving rotation of the back post 76, the backrest pivot linkage 54 with the first through fourth pivots 56, 58, 84, and 86 will cause the back post 76 to pivot about the two pivots 56 and 58 and simultaneously shift forward toward the seat box 60 as described previously herein.