LINKAGE MECHANISM AND RECLINING CHAIR HAVING SAME

Abstract

The invention discloses a linkage mechanism and a reclining chair having the same. The linkage mechanism has a forward mounting pivot for attaching the actuator to the footrest linkage and a rearward mounting unit for attaching the actuator to the lever link. The lever link is pivotally connected to the base mounting plate at the fulcrum pivot point. The fulcrum pivot attachment point is operably non-movable when the linkage mechanism is driven from one position to another position of the reclining chair, thereby, improving the operation stability of the reclining chair.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority to and the benefit of, pursuant to 35 U.S.C. §119(e), U.S. provisional patent application Ser. No. 61/845,002, filed Jul. 11, 2013, entitled “DEVELOPED DRIVE FOR POWER ROCKER RECLINER,” by Guo-Qiu Lu et al., which is incorporated herein in its entirety by reference.

This application also claims priority to and the benefit of, pursuant to 35 U.S.C. §119(a), Chinese Patent Application No. 201320257679.3, filed on May 10, 2013, in the State Intellectual Property Office of P.R. China, which is hereby incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The invention generally relates to a reclining chair, and more particular to a linkage mechanism and a reclining chair having the linkage mechanism.

BACKGROUND OF THE INVENTION

Reclining chairs find widespeard use. A reclining chair usually has a seat, a backrest, a pair of footrests and a pair of linkage mechanisms operably moveable among three positions, a fully upright position, a TV position and a fully reclined position. In the TV position, the seat and backrest are partially reclined and the footrest extended, while in the fully reclined position, the seat and backrest are fully reclined and the footrest extended.

Recently, electric motors have been applied to the reclining chair to facilitate the movement through the different positions. A conventional linkage mechanism includes a motor bellcrank having one end pivotally connected to a lift link that is in turn pivotally connected to a base mounting plate, the other end pivotally connected to a motor pivot bracket coupled to the motor, and a middle portion pivotally connected to a front lift link to define a fulcrum pivot therein. For such a design, however, the fulcrum pivot moves when the linkage mechanism is driven from one position to another position, which may cause the linkage mechanism to flex and fatigue during the operation and also the rear motor drive pivots upward to move close to the reclining chair when cycled.

Therefore, a heretofore unaddressed need exists in the art to address the aforementioned deficiencies and inadequacies.

SUMMARY OF THE INVENTION

The invention, in one aspect, relates to a linkage mechanism used in a reclining chair having an upright position, a TV position, and a fully reclined position.

In one embodiment, the linkage mechanism includes a base mounting plate for fixedly mounting the linkage mechanism onto a base assembly of the reclining chair; a backrest mounting bracket pivotally coupled to the base mounting plate; a seat mounting link having a front end portion and a rear end portion pivotally coupled to the backrest mounting bracket, and disposed movably relative to the base mounting plate; a footrest linkage pivotally coupled to the seat mounting link, a footrest drive mechanism pivotally coupled to the footrest linkage, the base mounting plate and the backrest mounting bracket for driving the footrest linkage operably between a retracted position and an TV position; and a reclining drive mechanism pivotally coupled to the backrest mounting bracket, the base mounting plate and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position.

The reclining drive mechanism has a reclining link having a first end portion pivotally connected to the backrest mounting bracket; a front pivot link having a first end portion pivotally connected to the second end portion of the reclining link and a second end portion pivotally connected to a first end portion of the base mounting plate; a lever link having a first end portion and a second end portion defining a middle portion therebetween, wherein the middle portion of the lever link is pivotally connected to the base mounting plate to define a fulcrum pivot therein, wherein the fulcrum pivot is operably non-movable relative to the base mounting plate; a connecting link having a first end portion pivotally connected to the reclining link at a position between the first and second end portions of the reclining link of the lever link, and a second end portion pivotally connected to the second portion of the lever link; and a rear motor drive bracket having a first end portion pivotally connected to the first end portion of the lever link, and a second end portion fixedly coupled to a linear actuator assembly for driving the lever link rotatably around the fulcrum pivot, so as to drive the reclining chair to be in the desired position.

In one embodiment, the footrest linkage comprises a scissor-type linkage.

In one embodiment, the footrest linkage comprises a first front footrest link, a second front footrest link, a first rear footrest link, a second rear footrest link and a footrest mounting bracket, each footrest link having a first end portion and a second end, wherein the first end portions of the first and second front footrest links and are pivotally connected to the footrest mounting bracket, and the second end portions of the first and second front footrest links and are pivotally connected to the first end portions of the first and second rear footrest links and, respectively, wherein the second front footrest link is pivotally connected to the first rear footrest link, wherein the second end portion of the first rear footrest link is pivotally connected to the front end portion of the seat mounting link, and wherein the second end portion of the second rear footrest link is pivotally connected to the seat mounting link at a position proximate to the front end portion of the seat mounting link.

In one embodiment, the footrest drive mechanism comprises: a footrest drive link having a first end portion pivotally connected to pivotally connected to the second rear footrest link at a position proximate to the second end portion of the second rear footrest link, and a second end portion; a rear stop link having a first end portion fixed mounted to the backrest mounting bracket, a second end portion and a guide slot formed at the second end portion; a rear pivot plate pivotally coupled to the backrest mounting bracket, a second end portion of the base mounting plate, a second end portion of the footrest drive link via the guide slot of the rear stop link; a wheel link having a first end portion pivotally connected to the rear pivot plate; and a wheel control link having a first end portion and a second end portion pivotally connected to the base mounting plate and the wheel link, respectively.

In one embodiment, the linkage mechanism further comprises a front motor drive bracket having a first end portion pivotally connected to the first rear footrest link at a position between the first and second end portions of the first rear footrest link, and a second end portion fixedly coupled to the linear actuator assembly.

In another aspect, the invention relates to a reclining chair comprising the reclining chair frame as disclosed above.

In yet another aspect, the invention relates to a reclining chair. The reclining chair includes a base assembly; a pair of linkage mechanisms coupled to the base assembly, wherein the pair of linkage mechanisms is disposed on either side of the reclining chair, and is substantially identical and mirror images of one another, and is interconnected to one another; and a linear actuator assembly coupled to the pair of linkage mechanisms for operably driving the reclining chair to be in a desired position that is corresponding to one of an upright position, a TV position, and a fully reclined position,

Each linkage mechanism includes a base mounting plate for fixedly mounting the linkage mechanism onto a base assembly of the reclining chair; a backrest mounting bracket pivotally coupled to the base mounting plate; a seat mounting link having a front end portion and a rear end portion pivotally coupled to the backrest mounting bracket, and disposed movably relative to the base mounting plate; a footrest linkage pivotally coupled to the seat mounting link, a footrest drive mechanism pivotally coupled to the footrest linkage, the base mounting plate and the backrest mounting bracket for driving the footrest linkage operably between a retracted position and an TV position; and a reclining drive mechanism pivotally coupled to the backrest mounting bracket, the base mounting plate and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position.

The reclining drive mechanism has a reclining link having a first end portion pivotally connected to the backrest mounting bracket; a front pivot link having a first end portion pivotally connected to the second end portion of the reclining link and a second end portion pivotally connected to a first end portion of the base mounting plate; a lever link having a first end portion and a second end portion defining a middle portion therebetween, wherein the middle portion of the lever link is pivotally connected to the base mounting plate to define a fulcrum pivot therein, wherein the fulcrum pivot is operably non-movable relative to the base mounting plate; a connecting link having a first end portion pivotally connected to the reclining link at a position between the first and second end portions of the reclining link of the lever link, and a second end portion pivotally connected to the second portion of the lever link; and a rear motor drive bracket having a first end portion pivotally connected to the first end portion of the lever link, and a second end portion fixedly coupled to a linear actuator assembly for driving the lever link rotatably around the fulcrum pivot, so as to drive the reclining chair to be in the desired position.

In one embodiment, the footrest linkage comprises a scissor-type linkage.

In one embodiment, the footrest linkage comprises a first front footrest link, a second front footrest link, a first rear footrest link, a second rear footrest link and a footrest mounting bracket, each footrest link having a first end portion and a second end, wherein the first end portions of the first and second front footrest links and are pivotally connected to the footrest mounting bracket, and the second end portions of the first and second front footrest links and are pivotally connected to the first end portions of the first and second rear footrest links and, respectively, wherein the second front footrest link is pivotally connected to the first rear footrest link, wherein the second end portion of the first rear footrest link is pivotally connected to the front end portion of the seat mounting link, and wherein the second end portion of the second rear footrest link is pivotally connected to the seat mounting link at a position proximate to the front end portion of the seat mounting link.

In one embodiment, the footrest drive mechanism comprises: a footrest drive link having a first end portion pivotally connected to pivotally connected to the second rear footrest link at a position proximate to the second end portion of the second rear footrest link, and a second end portion; a rear stop link having a first end portion fixed mounted to the backrest mounting bracket, a second end portion and a guide slot formed at the second end portion; a rear pivot plate pivotally coupled to the backrest mounting bracket, a second end portion of the base mounting plate, a second end portion of the footrest drive link via the guide slot of the rear stop link; a wheel link having a first end portion pivotally connected to the rear pivot plate; and a wheel control link having a first end portion and a second end portion pivotally connected to the base mounting plate and the wheel link, respectively.

In one embodiment, the linkage mechanism further comprises a front motor drive bracket having a first end portion pivotally connected to the first rear footrest link at a position between the first and second end portions of the first rear footrest link, and a second end portion fixedly coupled to the linear actuator assembly.

In one embodiment, the linear actuator assembly comprises: a front motor drive tube having a first end and a second end rigidly attached to the second end portions of the front motor drive brackets of the pair of linkage mechanisms, respectively; a rear motor drive tube having a first end and a second end rigidly attached to the second end portions of the rear motor drive brackets of the pair of linkage mechanisms, respectively; a front motor pivot bracket pivotally attached to a middle portion of the front motor drive tube; a rear motor attaching bracket rigidly attached to a middle portion of the rear motor drive tube; an actuator housing disposed between the front motor pivot bracket and the rear motor attaching bracket; an actuator yoke rigidly attached to the rear motor attaching bracket; and a linear actuator, wherein the linear actuator and the actuator yoke are slidably connected via the actuator housing.

In one embodiment, the base assembly comprises: a pair of support frames disposed the lateral sides of the reclining chair in parallel; and a pair of rockers, wherein each rocker is mounted to a respective support frame, and has a mounting plate onto which the base mounting plate of the linkage mechanism is rigidly mounted.

These and other aspects of the invention will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications therein may be affected without departing from the spirit and scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate one or more embodiments of the invention and, together with the written description, serve to explain the principles of the invention. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment.

FIG. 1 shows schematically a perspective view of a reclining chair having a pair of linkage mechanisms according to one embodiment of the invention.

FIG. 2A shows a side-view of the linkage mechanism utilized in the reclining chair in an upright position shown in FIG. 1.

FIG. 2B shows a side-view of a reclining drive mechanism of the linkage mechanism in the upright position shown in FIG. 2A.

FIG. 2C shows a side-view of the reclining chair shown in FIG. 1 having the linkage mechanism in the upright position.

FIG. 3A shows a side-view of the linkage mechanism utilized in the reclining chair in a TV position shown in FIG. 1.

FIG. 3B shows a side-view of a reclining drive mechanism of the linkage mechanism in the TV position shown in FIG. 3A.

FIG. 3C shows a side-view of the reclining chair shown in FIG. 1 having the linkage mechanism in the TV position.

FIG. 4A shows a side-view of the linkage mechanism utilized in the reclining chair in a fully reclined position shown in FIG. 1.

FIG. 4B shows a side-view of a reclining drive mechanism of the linkage mechanism in the fully reclined position shown in FIG. 4A.

FIG. 4C shows a side-view of the reclining chair shown in FIG. 1 having the linkage mechanism in the fully reclined position.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown.

This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.

The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used. Certain terms that are used to describe the invention are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the invention. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the invention.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower”, can therefore, encompasses both an orientation of “lower” and “upper,” depending of the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

As used herein, “around”, “about”, “substantially” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around”, “about” “substantially” or “approximately” can be inferred if not expressly stated.

The description will be made as to the embodiments of the invention in conjunction with the accompanying drawings in FIGS. 1, 2A-2C, 3A-3C and 4A-4C. In accordance with the purposes of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a linkage mechanism and a reclining chair having the linkage mechanism. The reclining chair operably has an upright position, a TV position and a fully reclined position.

Referring to FIGS. 1, 2A-2C, 3A-3C and 4A-4C, a linkage mechanism 100 is shown according to one embodiment of the invention. In this exemplary embodiment, the linkage mechanism 100 includes a base mounting plate 130, a backrest mounting bracket 140, a seat mounting link 120, a footrest linkage, and a footrest drive mechanism, and a reclining drive mechanism.

The base mounting plate 130 is adapted for fixedly (or rigidly) mounting (or attaching) the linkage mechanism 100 onto a base assembly of the reclining chair.

The backrest mounting bracket 140 is pivotally coupled to the base mounting plate 130.

The seat mounting link 120 has a front end portion and a rear end portion, and is disposed movably relative to the base mounting plate 130. The front end portion of the seat mounting link 120 is pivotally coupled to the footrest linkage, while the rear end portion of the seat mounting link 120 is pivotally coupled to the backrest mounting bracket 140.

The footrest linkage is pivotally coupled to the seat mounting link 120. Generally, the footrest linkage is a scissor-type linkage. In this exemplary embodiment, the footrest linkage comprises a first front footrest link 104, a second front footrest link 106, a first rear footrest link 104, a second rear footrest link 104 and a footrest mounting bracket 102. Each footrest link has a first end portion and a second end. The first end portions of the first and second front footrest links 104 and 106 are pivotally connected to the footrest mounting bracket 102. The second end portions of the first and second front footrest links 104 and 106 are pivotally connected to the first end portions of the first and second rear footrest links 108 and 110, respectively. The second front footrest link 106 is pivotally connected to the first rear footrest link 108. The second end portion of the first rear footrest link 108 is pivotally connected to the front end portion of the seat mounting link 120. The second end portion of the second rear footrest link 110 is pivotally connected to the seat mounting link 120 at a position proximate to the front end portion of the seat mounting link 120.

The footrest drive mechanism is pivotally coupled to the footrest linkage, the base mounting plate 130 and the backrest mounting bracket 140 for driving the footrest linkage operably between a retracted position and a TV position. The footrest drive mechanism in this exemplary embodiment includes a footrest drive link 122 having a first end portion pivotally connected to pivotally connected to the second rear footrest link 110 at a position proximate to the second end portion of the second rear footrest link 110, and a second end portion; a rear stop link 144 having a first end portion fixed mounted to the backrest mounting bracket 140, a second end portion and a guide slot 144a formed at the second end portion; a rear pivot plate 142 pivotally coupled to the backrest mounting bracket 140, a second end portion of the base mounting plate 130, a second end portion of the footrest drive link 122 via the guide slot 144a of the rear stop link 144; a wheel link 146 having a first end portion pivotally connected to the rear pivot plate 142; and a wheel control link 148 having a first end portion and a second end portion pivotally connected to the base mounting plate 130 and the wheel link 146, respectively.

The reclining drive mechanism is pivotally coupled to the backrest mounting bracket 140, the base mounting plate 130 and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position. In this exemplary embodiment, the reclining drive mechanism has a reclining link 132, a front pivot link 134, a lever link 136, a connecting link 138, and a rear motor drive bracket 160.

The reclining link 132 has a first end portion pivotally connected to the backrest mounting bracket 140, and a second end portion pivotally connected to a first end portion of the front pivot link 134.

The front pivot link 134 has the first end portion pivotally connected to the second end portion of the reclining link 132 and a second end portion pivotally connected to a first end portion of the base mounting plate 130.

The lever link 136 has a first end portion and a second end portion defining a middle portion therebetween. The middle portion of the lever link 136 is pivotally connected to the base mounting plate 130 to define a fulcrum pivot 136c therein. According to the invention, the fulcrum pivot 136c is operably non-movable relative to the base mounting plate 130.

The connecting link 138 has a first end portion pivotally connected to the reclining link 132 at a position 138a between the first and second end portions of the reclining link 132 of the lever link 136, and a second end portion pivotally connected to the second portion of the lever link 136.

The rear motor drive bracket 160 has a first end portion pivotally connected to the first end portion of the lever link 136, and a second end portion fixedly coupled to a linear actuator assembly for driving the lever link 136 rotatably around the fulcrum pivot 136c, so as to drive the reclining chair to be in the desired position.

The linkage mechanism 100 also includes a front motor drive bracket 150 having a first end portion pivotally connected to the first rear footrest link 108 at a position between the first and second end portions of the first rear footrest link 108, and a second end portion fixedly coupled to the linear actuator assembly.

Preferably, the linkage mechanism 100 is made from durable materials such as steel, alloy, plastic, wood, or any combination of them, as known to people skilled in the art.

Again, referring to FIGS. 1, 2A-2C, 3A-3C and 4A-4C, and particularly to FIGS. 1, 2C, 3C and 4C, a reclining chair or seating unit 10 is schematically shown according to one embodiment of the invention. The reclining chair 10 includes a base assembly placed on a floor, a pair of linkage mechanisms 100 coupled to the base assembly, a backrest 196, a seat 198 and a footrest 102 supported by the linkage mechanism 100, armrests 194 mounted onto the base assembly, and a linear actuator assembly coupled to the pair of linkage mechanisms for operably driving the reclining chair 10 to be in a desired position that is corresponding to one of an upright or close position, a semi-reclined or TV position, and a fully reclined position. The linkage mechanism 100 has a scissor-type footrest linkage assembly that is operably movable in a retracted position and an extended position, and is configured such that the seat 198, the backrest 196 and the footrest 102 are movable among the upright position, the TV position, and the fully reclined position.

The closed position, as shown in FIGS. 2A-2C, is generally a normal non-reclined sitting position with the seat 198 in a generally horizontal position and the backrest 196 generally upright and in a substantial, perpendicular-biased relation to the seat 198. The scissor-type footrest linkage and the footrests 102 are in a refracted position. In the TV position, the footrest linkage and the footrests 102 are extended forward and disposed generally horizontal, while the backrest 196 remains substantially perpendicular to the seat 198. The backrest 196 and the seat 198 define an angle, a, as shown in FIGS. 3A-3C. The scissor-type footrest linkage and the footrests 102 are in an extended position. In the fully reclined position, the backrest 196 is rotated rearward by the linkage mechanism 100 and biased in a rearward inclination angle, β, in relation to the seat 198, where β>α, as shown in FIGS. 4A-4C. The scissor-type footrest linkage and the footrests 102 are also in the extended position.

In this exemplary embodiment shown in FIG. 1, the base assembly includes a pair of support frames 190 parallel-placed on a floor at two lateral sides of the reclining chair 10, and a pair of rockers 180. Each rocker 180 is mounted onto a respective support frame 190, and has a mounting plate 182 onto which the base mounting plate 130 of the linkage mechanism 100 is rigidly mounted.

As shown in FIG. 1, the pair of linkage mechanisms 100 is located on opposite sides of the reclining chair 10 and interconnected by appropriate cross pieces, as necessary, for example, a front motor drive tube 152 and a rear motor drive tube 162. Since the pair of linkage mechanisms 100 on either side of the reclining chair are substantially identical and mirror images of one another, as shown in FIG. 1, only one linkage mechanism 100 is described herein for the purposes of simplicity.

In this exemplary embodiment, the linkage mechanism 100 includes a base mounting plate 130, a backrest mounting bracket 140, a seat mounting link 120, a footrest linkage, and a footrest drive mechanism, and a reclining drive mechanism.

The base mounting plate 130 is fixedly (or rigidly) mounted (or attached) onto the mounting plate 182 of the rocker 180 of the base assembly of the reclining chair 10. The backrest mounting bracket 140 is adapted for supporting and holding the backrest 196 and pivotally coupled to the base mounting plate 130.

The seat mounting link 120 is adapted for supporting the seat 198, and disposed movably relative to the base mounting plate 130. The seat mounting link 120 has a front end portion and a rear end portion. The front end portion of the seat mounting link 120 is pivotally coupled to the footrest linkage, while the rear end portion of the seat mounting link 120 is pivotally coupled to the backrest mounting bracket 140.

The footrest linkage is pivotally coupled to the seat mounting link 120. Generally, the footrest linkage is a scissor-type linkage. In this exemplary embodiment, the footrest linkage comprises a first front footrest link 104, a second front footrest link 106, a first rear footrest link 104, a second rear footrest link 104 and a footrest mounting bracket 102. Each footrest link has a first end portion and a second end. The first end portions of the first and second front footrest links 104 and 106 are pivotally connected to the footrest mounting bracket 102. The second end portions of the first and second front footrest links 104 and 106 are pivotally connected to the first end portions of the first and second rear footrest links 108 and 110, respectively. The second front footrest link 106 is pivotally connected to the first rear footrest link 108. The second end portion of the first rear footrest link 108 is pivotally connected to the front end portion of the seat mounting link 120. The second end portion of the second rear footrest link 110 is pivotally connected to the seat mounting link 120 at a position proximate to the front end portion of the seat mounting link 120.

The footrest drive mechanism is pivotally coupled to the footrest linkage, the base mounting plate 130 and the backrest mounting bracket 140 for driving the footrest linkage operably between a retracted position and a TV position. The footrest drive mechanism in this exemplary embodiment includes a footrest drive link 122 having a first end portion pivotally connected to pivotally connected to the second rear footrest link 110 at a position proximate to the second end portion of the second rear footrest link 110, and a second end portion; a rear stop link 144 having a first end portion fixed mounted to the backrest mounting bracket 140, a second end portion and a guide slot 144a formed at the second end portion; a rear pivot plate 142 pivotally coupled to the backrest mounting bracket 140, a second end portion of the base mounting plate 130, a second end portion of the footrest drive link 122 via the guide slot 144a of the rear stop link 144; a wheel link 146 having a first end portion pivotally connected to the rear pivot plate 142; and a wheel control link 148 having a first end portion and a second end portion pivotally connected to the base mounting plate 130 and the wheel link 146, respectively.

The reclining drive mechanism is pivotally coupled to the backrest mounting bracket 140, the base mounting plate 130 and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position. In this exemplary embodiment, the reclining drive mechanism has a reclining link 132, a front pivot link 134, a lever link 136, a connecting link 138, and a rear motor drive bracket 160.

The reclining link 132 has a first end portion pivotally connected to the backrest mounting bracket 140, and a second end portion pivotally connected to a first end portion of the front pivot link 134.

The front pivot link 134 has the first end portion pivotally connected to the second end portion of the reclining link 132 and a second end portion pivotally connected to a first end portion of the base mounting plate 130.

The lever link 136 has a first end portion and a second end portion defining a middle portion therebetween. The middle portion of the lever link 136 is pivotally connected to the base mounting plate 130 to define a fulcrum pivot 136c therein. According to the invention, the fulcrum pivot 136c is operably non-movable relative to the base mounting plate 130.

The connecting link 138 has a first end portion pivotally connected to the reclining link 132 at a position 138a between the first and second end portions of the reclining link 132 of the lever link 136, and a second end portion pivotally connected to the second portion of the lever link 136.

The rear motor drive bracket 160 has a first end portion pivotally connected to the first end portion of the lever link 136, and a second end portion fixedly attached to a linear actuator assembly via the rear motor drive tube 162, for driving the lever link 136 rotatably around the fulcrum pivot 136c, so as to drive the reclining chair to be in the desired position.

The linkage mechanism 100 also includes a front motor drive bracket 150 having a first end portion pivotally connected to the first rear footrest link 108 at a position between the first and second end portions of the first rear footrest link 108, and a second end portion fixedly attached to the linear actuator assembly via the front motor drive tube 152.

As shown in FIG. 1, the linear actuator assembly includes a front motor drive tube 152 having a first end and a second end rigidly attached to the second end portions of the front motor drive brackets 150 of the pair of linkage mechanisms, respectively; a rear motor drive tube 162 having a first end and a second end rigidly attached to the second end portions of the rear motor drive brackets 160 of the pair of linkage mechanisms, respectively; a front motor pivot bracket 172 pivotally attached to a middle portion of the front motor drive tube 152; a rear motor attaching bracket 174 rigidly attached to a middle portion of the rear motor drive tube 162; an actuator housing 178 disposed between the front motor pivot bracket 172 and the rear motor attaching bracket 174; an actuator yoke 176 rigidly attached to the rear motor attaching bracket 174; and a linear actuator 170. The linear actuator 170 and the actuator yoke 176 are slidably connected via the actuator housing 178. The linear actuator assembly also has with electronic control meaning for adjusting positions of the reclining chair among the closed position, the TV position and the full reclined position.

The reclining chair 10 can be moved forward and rearward in a rocking motion in a closed position. Movements to the TV and full reclined positions are restricted by the linear actuator 170. The linear actuator 170 contains a threaded screw shaft that when rotated causes a matching threaded actuator yoke 176 to move forward or rearward over the actuator housing 178. The linear actuator 170 has a pivoting connection 172 to the front motor drive tube 152 that is rigidly attached to the first rear footrest link 108 though the front motor drive bracket 150. Such an attachment arrangement allows the front motor drive tube 152 to supply adequate torque resistance between left and right hand footrest assemblies and maintains a mirrored movement of the assemblies while maintaining freedom of movement through pivoting connection 172. The moveable actuator yoke 176 is rigidly attached to the rear motor attach bracket 174 at an attachment point 175. In one embodiment, the rear motor attach bracket 174 is solidly welded to the rear motor drive tube 162, so as to creates a ridged assembly of the actuator yoke 176, the rear motor attach bracket 174 and the rear motor drive tube 162. The rear motor drive bracket 160 is rigidly connected to the end of the rear motor drive tube 162 and has a pivoting connection to the first end portion of the lever link 136 at the lever link pivot 136a. The lever link pivot 136a allows freedom for the rear of the linear actuator assembly to pivot up and down during cycling. The lever link 136 has the first end portion pivotally connected to the rear motor drive bracket 160 at the lever link pivot 136a, the second end portion pivotally connected to the connecting link 138 at a pivot 136b, and the middle portion pivotally connected to the base mounting bracket 136 at the fulcrum pivot attachment point 136c. The connecting link 138 is pivotally connected to the reclining link 132 at lift link upper pivot 138a. The fulcrum pivot attachment point 136c is operably non-movable, that is, the fulcrum pivot attachment point 136c is still when the linkage mechanism 100 is driven from one position to another position of the reclining chair 10, so that the operation stability of the reclining chair 10 is improved.

In operation, the movement of the reclining chair from one position to another position is activated by the movement of the linear actuator yoke 176 via an electronic control. The movement of the linear actuator yoke 176 causes the distance between the lever link pivot (fulcrum pivot) 136c and the front motor pivot 172 to increase or decrease dependent on a motor direction. The length of the movement is controlled at each end by limit switches contained in the actuator housing 178. The movement may be stopped also at any time via the electronic controller. In the closed position, the distance between the fulcrum pivot 136c and the front motor pivot 172 is at the shortest limit. Activating of the controller moves the linear actuator yoke 176 rearward along the actuator housing 178, thereby, moving the rear motor attach bracket 174, the rear motor drive tube 162 and the rear motor drive bracket 160 rearward simultaneously as on unit. As the distance between the fulcrum pivot 136c and the front motor pivot 172 increases, the footrest 102 moves out and up. This movement continues until the first rear footrest link 108 reaches an interference position against a TV stop 105 and the TV position is attained. The interference position of the first rear footrest link 108 against the TV stop 105 stops the forward movement of the front motor pivot 172, so if the user of the reclining chair 10 continues to engage the electronic control, the linear actuator yoke 176 is forced to move rearward along with the rear motor attach bracket 174, the rear motor drive tube 162 and the rear motor drive bracket 160 and the lever link 136. The rearward movement of the linear actuator yoke 176 causes a counterclockwise rotation of the lever link 136 around the fulcrum pivot 136c that is not movable. The rotation of the lever link 136 also causes a counterclockwise rotation of the pivot 136b where the connecting link 138 is pivotally attached to the lever link 136. The counterclockwise rotation of the pivot 136b is more or less in an upward direction, which this movement forces the connecting link 138 to move more or less upward and drive the reclining link 132 upward through the pivotally attached location of the pivot 138a. The upward movement of the recline link 132 causes the back of the reclining chair 10 to move rearward until the extended position limit switch of the linear actuator 170 is reached. A rear linear actuator attachment position to the lever that operably maintains the relative position of the rear of the linear actuator away from the seat as the reclining chair is moved to the full reclined position.

The movement from the full reclined position to the TV position and then to the closed position is achieved by reversing the linear actuator 170 with the electronic controller that causes the distance between the fulcrum pivot 136c and the front motor pivot 172 to be reduced, thereby, causing first the clockwise rotation of the lever link 136 around the fulcrum pivot 136c, which results in the lowering of the connecting link 138 and the reclining link 132 until the TV position is reached. Then continuously retracting of the linear actuator 170 brings the fulcrum point 136c and the front motor pivot 172 closer together causes the clockwise rotation of the first rear footrest link 108 until the contracted limit switch is reached and the reclining chair is fully closed. According to the invention, the linkage mechanism has a forward mounting pivot for attaching the actuator to the footrest linkage and a rearward mounting unit for attaching the actuator to the lever link. The lever link is pivotally connected to the base mounting plate at the fulcrum pivot point. The fulcrum pivot attachment point is operably non-movable, i.e., the fulcrum pivot attachment point is still when the linkage mechanism is driven from one position to another position of the reclining chair, so that the operation stability of the reclining chair is improved.

The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.

The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to enable others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the invention pertains without departing from its spirit and scope. Accordingly, the scope of the invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.

Claims

1. A linkage mechanism used in a reclining chair having an upright position, a TV position, and a fully reclined position, comprising:

(a) a base mounting plate for fixedly mounting the linkage mechanism onto a base assembly of the reclining chair;

(b) a backrest mounting bracket pivotally coupled to the base mounting plate;

(c) a seat mounting link having a front end portion and a rear end portion pivotally coupled to the backrest mounting bracket, and disposed movably relative to the base mounting plate;

(d) a footrest linkage pivotally coupled to the seat mounting link,

(e) a footrest drive mechanism pivotally coupled to the footrest linkage, the base mounting plate and the backrest mounting bracket for driving the footrest linkage operably between a retracted position and an TV position; and

(f) a reclining drive mechanism pivotally coupled to the backrest mounting bracket, the base mounting plate and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position, wherein the reclining drive mechanism comprises: (i) a reclining link having a first end portion pivotally connected to the backrest mounting bracket; (ii) a front pivot link having a first end portion pivotally connected to the second end portion of the reclining link and a second end portion pivotally connected to a first end portion of the base mounting plate; (iii) a lever link having a first end portion and a second end portion defining a middle portion therebetween, wherein the middle portion of the lever link is pivotally connected to the base mounting plate to define a fulcrum pivot therein, wherein the fulcrum pivot is operably non-movable relative to the base mounting plate; (iv) a connecting link having a first end portion pivotally connected to the reclining link at a position between the first and second end portions of the reclining link of the lever link, and a second end portion pivotally connected to the second portion of the lever link; and (v) a rear motor drive bracket having a first end portion pivotally connected to the first end portion of the lever link, and a second end portion fixedly coupled to a linear actuator assembly for driving the lever link rotatably around the fulcrum pivot, so as to drive the reclining chair to be in the desired position.

2. The linkage mechanism of claim 1, wherein the footrest linkage comprises a scissor-type linkage.

3. The linkage mechanism of claim 2, wherein the footrest linkage comprises a first front footrest link, a second front footrest link, a first rear footrest link, a second rear footrest link and a footrest mounting bracket, each footrest link having a first end portion and a second end, wherein the first end portions of the first and second front footrest links and are pivotally connected to the footrest mounting bracket, and the second end portions of the first and second front footrest links and are pivotally connected to the first end portions of the first and second rear footrest links and, respectively, wherein the second front footrest link is pivotally connected to the first rear footrest link, wherein the second end portion of the first rear footrest link is pivotally connected to the front end portion of the seat mounting link, and wherein the second end portion of the second rear footrest link is pivotally connected to the seat mounting link at a position proximate to the front end portion of the seat mounting link.

4. The linkage mechanism of claim 3, wherein the footrest drive mechanism comprises:

(a) a footrest drive link having a first end portion pivotally connected to pivotally connected to the second rear footrest link at a position proximate to the second end portion of the second rear footrest link, and a second end portion;

(b) a rear stop link having a first end portion fixed mounted to the backrest mounting bracket, a second end portion and a guide slot formed at the second end portion;

(c) a rear pivot plate pivotally coupled to the backrest mounting bracket, a second end portion of the base mounting plate, a second end portion of the footrest drive link via the guide slot of the rear stop link;

(d) a wheel link having a first end portion pivotally connected to the rear pivot plate; and

(e) a wheel control link having a first end portion and a second end portion pivotally connected to the base mounting plate and the wheel link, respectively.

5. The linkage mechanism of claim 3, further comprising a front motor drive bracket having a first end portion pivotally connected to the first rear footrest link at a position between the first and second end portions of the first rear footrest link, and a second end portion fixedly coupled to the linear actuator assembly.

6. A reclining chair comprising the linkage mechanism of claim 1.

7. A reclining chair, comprising: wherein each linkage mechanism comprising:

a base assembly;

a pair of linkage mechanisms coupled to the base assembly, wherein the pair of linkage mechanisms is disposed on either side of the reclining chair, and is substantially identical and mirror images of one another, and is interconnected to one another; and

a linear actuator assembly coupled to the pair of linkage mechanisms for operably driving the reclining chair to be in a desired position that is corresponding to one of an upright position, a TV position, and a fully reclined position,

(a) a base mounting plate for fixedly mounting the linkage mechanism onto the base assembly;

(b) a backrest mounting bracket pivotally coupled to the base mounting plate;

(c) a seat mounting link having a front end portion and a rear end portion pivotally coupled to the backrest mounting bracket, and disposed movably relative to the base mounting plate;

(c) a footrest linkage pivotally coupled to the seat mounting link,

(d) a footrest drive mechanism pivotally coupled to the footrest linkage, the base mounting plate and the backrest mounting bracket for driving the footrest linkage operably between a retracted position and an TV position; and

(e) a reclining drive mechanism pivotally coupled to the backrest mounting bracket, the base mounting plate and the footrest drive mechanism, for driving the reclining chair to be in a desired position that is corresponding to one of the upright position, the TV position, and the fully reclined position, wherein the reclining drive mechanism comprises: (i) a reclining link having a first end portion pivotally connected to the backrest mounting bracket; (ii) a front pivot link having a first end portion pivotally connected to the second end portion of the reclining link and a second end portion pivotally connected to a first end portion of the base mounting plate; (iii) a lever link having a first end portion and a second end portion defining a middle portion therebetween, wherein the middle portion of the lever link is pivotally connected to the base mounting plate to define a fulcrum pivot therein, wherein the fulcrum pivot is operably non-movable relative to the base mounting plate; (iv) a connecting link having a first end portion pivotally connected to the reclining link at a position between the first and second end portions of the reclining link of the lever link, and a second end portion pivotally connected to the second portion of the lever link; and (v) a rear motor drive bracket having a first end portion pivotally connected to the first end portion of the lever link, and a second end portion fixedly coupled to the linear actuator assembly for driving the lever link rotatably around the fulcrum pivot, so as to drive the reclining chair to be in the desired position.

8. The reclining chair of claim 7, wherein the footrest linkage comprises a scissor-type linkage.

9. The reclining chair of claim 8, wherein the footrest linkage comprises a first front footrest link, a second front footrest link, a first rear footrest link, a second rear footrest link and a footrest mounting bracket, each footrest link having a first end portion and a second end, wherein the first end portions of the first and second front footrest links and are pivotally connected to the footrest mounting bracket, and the second end portions of the first and second front footrest links and are pivotally connected to the first end portions of the first and second rear footrest links and, respectively, wherein the second front footrest link is pivotally connected to the first rear footrest link, wherein the second end portion of the first rear footrest link is pivotally connected to the front end portion of the seat mounting link, and wherein the second end portion of the second rear footrest link is pivotally connected to the seat mounting link at a position proximate to the front end portion of the seat mounting link.

10. The reclining chair of claim 9, wherein the footrest drive mechanism comprises:

(a) a footrest drive link having a first end portion pivotally connected to pivotally connected to the second rear footrest link at a position proximate to the second end portion of the second rear footrest link, and a second end portion;

(b) a rear stop link having a first end portion fixed mounted to the backrest mounting bracket, a second end portion and a guide slot formed at the second end portion;

(c) a rear pivot plate pivotally coupled to the backrest mounting bracket, a second end portion of the base mounting plate, a second end portion of the footrest drive link via the guide slot of the rear stop link;

(d) a wheel link having a first end portion pivotally connected to the rear pivot plate; and

(e) a wheel control link having a first end portion and a second end portion pivotally connected to the base mounting plate and the wheel link, respectively.

11. The reclining chair of claim 9, wherein the linkage mechanism further comprises a front motor drive bracket having a first end portion pivotally connected to the first rear footrest link at a position between the first and second end portions of the first rear footrest link, and a second end portion fixedly coupled to the linear actuator assembly.

12. The reclining chair of claim 7, wherein the linear actuator assembly comprises:

(a) a front motor drive tube having a first end and a second end rigidly attached to the second end portions of the front motor drive brackets of the pair of linkage mechanisms, respectively;

(b) a rear motor drive tube having a first end and a second end rigidly attached to the second end portions of the rear motor drive brackets of the pair of linkage mechanisms, respectively;

(c) a front motor pivot bracket pivotally attached to a middle portion of the front motor drive tube;

(d) a rear motor attaching bracket rigidly attached to a middle portion of the rear motor drive tube;

(e) an actuator housing disposed between the front motor pivot bracket and the rear motor attaching bracket;

(f) an actuator yoke rigidly attached to the rear motor attaching bracket; and

(g) a linear actuator, wherein the linear actuator and the actuator yoke 340 are slidably connected via the actuator housing 330.

13. The reclining chair of claim 1, wherein the base assembly comprises:

(a) a pair of support frames disposed the lateral sides of the reclining chair in parallel; and

(b) a pair of rockers, wherein each rocker is mounted to a respective support frame, and has a mounting plate onto which the base mounting plate of the linkage mechanism is rigidly mounted.