ROCKING FURNITURE MEMBER
A furniture member including a seat base, a seat assembly, a first and second rocker member, and a first and second rocker spring assembly. The seat assembly is movable relative to the seat base. The first and second rocker members are fixedly attached to the seat frame assembly. Each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base. The first and second rocker spring assemblies are secured to the seat base and the first and second rocker members, respectively. The first rocker spring assembly includes a first mount bracket, a second mount bracket, and a first spring that extends between the first and second mount brackets. The second rocker spring assembly includes a third mount bracket, a fourth mount bracket, and a second spring that extends between the third and fourth mount brackets.
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This application claims the benefit of U.S. Provisional Application No. 63/442,478, filed on Feb. 1, 2023. The entire disclosure of the above application is incorporated herein by reference.
FIELDThe present disclosure relates to a furniture member, and more specifically to a rocking furniture member.
BACKGROUNDThis section provides background information related to the present disclosure and is not necessarily prior art.
Furniture members such as chairs, sofas, loveseats, sectionals, and the like may include a seatback that is movable relative to a seat bottom between an upright position and a reclined position, using a recliner mechanism. Additionally, some furniture members may include a legrest mechanism that allows an occupant of the furniture member to move a legrest panel or platform between a retracted position and an extended position to support the legs and/or feet of the occupant. Furthermore, some furniture members may include a rocker mechanism that allows the occupant of the furniture member to rock the furniture member between a rearward-tilt rocking position and a forward-tilt rocking position.
However, some furniture members are highly dependent on a narrow selection of materials, which can result in inefficiencies during production. Additionally, some current legrest mechanisms and rocker mechanisms are limited in their range of motion and yield poor performance, which thereby limits the occupant's quality of experience and ability to obtain a comfortable position. The present disclosure provides an improved furniture member that allows for a wider selection of materials and improved performance of the legrest mechanism and rocker mechanism.
SUMMARYThis section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a furniture member that includes a seat base, a seat assembly, a first rocker member, a second rocker member, a first rocker spring assembly, and a second rocker spring assembly. The seat assembly has a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom. The seat assembly is movable relative to the seat base between a first rocking position and a second rocking position. The first rocker member and the second rocker member are fixedly attached to the seat frame assembly. Each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base. The first rocker spring assembly and the second rocker spring assembly are secured to the seat base and the first and second rocker members, respectively. The first rocker spring assembly include a first mount bracket that is fixedly attached to the first rocker member, a second mount bracket that is fixedly attached to the seat base, and a left-handed spring that extends between the first and second mount brackets. The second rocker spring assembly includes a third mount bracket that is fixedly attached to the second rocker member, a fourth mount bracket that is fixedly attached to the seat base, and a right-handed spring that extends between the third and fourth mount brackets.
In some configurations of the furniture member of the above paragraph, the left-handed spring includes a coil that extend in a counterclockwise direction as the coil extends from a top end of the left-handed spring to a bottom end of the left-handed spring.
In some configurations of the furniture member of any one or more of the above paragraphs, the right-handed spring includes a coil that extend in a clockwise direction as the coil extends from a top end of the right-handed spring to a bottom end of the right-handed spring.
In some configurations of the furniture member of any one or more of the above paragraphs, the first and second mount brackets include an outboard wall, a base, and an inboard wall that cooperate to substantially form a U-shape.
In some configurations of the furniture member of any one or more of the above paragraphs, the inboard wall of the first and second mount brackets includes a slot that receives a portion of the left-handed spring.
In some configurations of the furniture member of any one or more of the above paragraphs, the base includes a hook that secures the left-handed spring to the first and second mount brackets.
In some configurations of the furniture member of any one or more of the above paragraphs, the base includes a raised alignment member that directly contacts an inner perimeter edge of the left-handed spring to secure the left-handed spring to the first and second mount brackets.
In some configurations of the furniture member of any one or more of the above paragraphs, the first rocker spring assembly includes a first limit wire that extends through the first mount bracket, the left-handed spring, and the second mount bracket.
In some configurations of the furniture member of any one or more of the above paragraphs, the second rocker spring assembly includes a second limit wire that extends through the third mount bracket, the right-handed spring, and the fourth mount bracket.
In some configurations of the furniture member of any one or more of the above paragraphs, the first and second limit wires defines a range of motion of the seat assembly between the first and second rocking positions.
In some configurations of the furniture member of any one or more of the above paragraphs, the furniture member further includes a rack assembly. The rack assembly includes a first side that is fixedly attached to the seat frame assembly and a second side that includes a plurality of teeth.
In some configurations of the furniture member of any one or more of the above paragraphs, the furniture member further includes a pawl assembly movable relative to the seat base between an engaged position and a disengaged position. The pawl assembly includes a pawl, a mount bracket attached to the seat base, and a spring including a first wall that is secured to the pawl and a second wall that is secured to the mount bracket.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl is formed from a hardened material.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl assembly includes a pawl cap that is disposed at a top end of the pawl. The pawl cap moves into contact with one of the plurality of teeth of the rack assembly when the pawl assembly is in the engaged position and moves out of contact with the plurality of teeth of the rack assembly when the pawl assembly is in the disengaged position.
In some configurations of the furniture member of any one or more of the above paragraphs, the furniture member further includes a legrest mechanism including a legrest platform. The legrest platform is movable relative to the seat base between a retracted position and an extended position.
In some configurations of the furniture member of any one or more of the above paragraphs, the legrest mechanism includes a drive rod supported by the seat assembly, a pantograph linkage driven by drive rod and attached to the legrest platform, and a drive link attached to the pantograph linkage. The pantograph linkage is movable relative to the seat base between a retracted position and an extended position. The drive link includes a first end that is fixedly attached to the drive rod and a second end that is rotatably attached to the pantograph linkage.
In some configurations of the furniture member of any one or more of the above paragraphs, the drive link and pantograph linkage are configured in an over-center condition when the legrest platform is in the extended position.
In another form, the present disclosure provides a furniture member that includes a seat base, a seat assembly, a legrest mechanism, a rack mechanism, and a pawl mechanism. The seat assembly includes a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom. The seat assembly is movable relative to the seat base between a forward-tilt rocking position and a rearward-tilt rocking position. The legrest mechanism includes a legrest platform. The legrest platform is movable relative to the seat base between a retracted position and an extended position. The rack assembly includes a first side that is fixedly attached to the seat frame assembly and a second side that includes a plurality of teeth. The pawl assembly is movable relative to the seat base between an engaged position and a disengaged position. The pawl assembly includes a pawl, a pawl cap disposed at a top end of the pawl, a mount bracket attached to the seat base, and a spring including a first wall that abuts the pawl and a second wall that abuts the mount bracket. The spring is movable relative to the mount bracket between a first position and a second position. When the legrest platform is in the extended position, the pawl cap abuts one of the plurality of teeth and restricts the seat assembly from moving between the forward-tilt rocking position and the rearward-tilt rocking position.
In some configurations of the furniture member of the above paragraph, the rack assembly includes a bracket disposed at the first side and a ratchet rack that is received in the bracket.
In some configurations of the furniture member of any one or more of the above paragraphs, the ratchet rack is formed from at least one of a polymeric material, an elastomeric material and a metal material.
In some configurations of the furniture member of any one or more of the above paragraphs, the metal material is a hardened material.
In some configurations of the furniture member of any one or more of the above paragraphs, the ratchet rack includes a set of plates. Each of the plates include the plurality of teeth and the plurality of teeth of each plate are aligned with each other.
In some configurations of the furniture member of any one or more of the above paragraphs, the set of plates includes three plates.
In some configurations of the furniture member of any one or more of the above paragraphs, the rack assembly includes a back wall positioned at the first side and a pair of sidewalls that extend from opposing ends of the back wall to form a U-shape. The plurality of teeth are formed in the pair of sidewalls.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap includes a flange that extends over the top end of the pawl.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap is secured to the pawl using a mechanical fastener.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap includes a top wall that covers the top end of the pawl and opposing side walls that extend from the top wall and abut opposing surfaces of the pawl.
In some configurations of the furniture member of any one or more of the above paragraphs, the top wall of the pawl cap has a first depth and each tooth of the plurality of teeth has a second depth, wherein the first depth is equal to or greater than the second depth.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap is formed from at least one of a polymeric material, an elastomeric material or and metal material.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl includes a first hook that receives the first wall of the spring and the mount bracket includes a second hook that receives the second wall of the spring.
In another form, the present disclosure provides a furniture member that includes a seat base, a seat assembly, a first rocker member, a second rocker member, a second rocker spring assembly, a rack assembly, and a pawl assembly. The seat assembly has a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom. The seat assembly is movable relative to the seat base between a first rocking position and a second rocking position. The first rocker member and the second rocker member fixedly attached to the seat frame assembly. Each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base. The first rocker spring assembly is secured to the seat base and the first rocker member. The first rocker spring assembly includes a left-handed spring. The second rocker spring assembly secured to the seat base and the second rocker member. The second rocker spring assembly includes a right-handed spring. The rack assembly includes a first side that is fixedly attached to the seat frame assembly and a second side that includes a plurality of teeth. The pawl assembly is movable between an engaged position and a disengaged position. The pawl assembly includes a pawl, a pawl cap disposed at a top end of the pawl, a mount bracket attached to the seat base, and a spring including a first wall that abuts the pawl and a second wall that abuts the mount bracket. The spring is movable between a first position and a second position.
In some configurations of the furniture member of the above paragraph, when the pawl assembly is in the disengaged position, the seat assembly is movable between the first rocking position and the second rocking position.
In some configurations of the furniture member of any one or more of the above paragraphs, when the pawl assembly is in the engaged position, the seat assembly is restricted from movement between the first rocking position and the second rocking position.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap abuts one of the plurality of teeth of the rack assembly.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap covers the top end of the pawl.
In some configurations of the furniture member of any one or more of the above paragraphs, the pawl cap is formed from a polymeric material or an elastomeric material.
In some configurations of the furniture member of any one or more of the above paragraphs, the rack assembly includes a bracket and a ratchet rack that is received in the bracket.
In some configurations of the furniture member of any one or more of the above paragraphs, the ratchet rack is formed from a polymeric or an elastomeric material.
In some configurations of the furniture member of any one or more of the above paragraphs, the ratchet rack is formed from the same material as the pawl cap.
In yet another form, the present disclosure provides a furniture member that includes a seat assembly and a legrest mechanism. The legrest mechanism is attached to the seat assembly. The legrest mechanism includes a drive rod supported by the seat assembly, a legrest platform, a pantograph linkage driven by drive rod and attached to the legrest platform, and a drive link attached to the pantograph linkage. The pantograph linkage is movable between a retracted position and an extended position. The drive link includes a first end that is fixedly attached to the drive rod and a second end that is rotatably attached to the pantograph linkage. The drive link and pantograph linkage are configured in an over-center condition when the legrest mechanism is in the extended position.
In some configurations of the furniture member of the above paragraph, the pantograph linkage includes a first support link and the first support link extends between a first end that is attached to the drive link and a second end.
In some configurations of the furniture member of any one or more of the above paragraphs, the drive link and the first support link of the pantograph linkage are configured in the over-center condition when the legrest mechanism is in the extended position.
In some configurations of the furniture member of any one or more of the above paragraphs, the first support link is substantially linear.
In some configurations of the furniture member of any one or more of the above paragraphs, the drive link and first support link are configured in a center condition when the drive link and first support link are axially aligned.
In some configurations of the furniture member of any one or more of the above paragraphs, rotation of the drive rod by approximately 1 degree in a first direction from the center condition places the drive link and pantograph linkage in the over-center condition.
In some configurations of the furniture member of any one or more of the above paragraphs, rotation of the drive rod by approximately 5 degrees in a first direction from the center condition places the drive link and pantograph linkage in the over-center condition.
In some configurations of the furniture member of any one or more of the above paragraphs, rotation of the drive rod by approximately 8 degrees in a first direction from the center condition places the drive link and pantograph linkage in the over-center condition.
In yet another form, the present disclosure provides a furniture member that includes a seat base, a seatback, a seat bottom, and a pair of linkages. The seatback includes a pair of first panels that are spaced apart from each other and a second panel that extends between the pair of first panels. The seat bottom includes a pair of first support beams and a pair of second support beams. Each of the pair of first support beams extend between the pair of second support beams and include a first flange and a second flange. The pair of linkages pivotally attach the pair of first panels of the seatback and the pair of first support beams of the seat bottom. The pair of linkages are configured to move the seatback and seat bottom relative to the seat base between an upright position and a reclined position. Each the pair of linkages are rotatably attached to the first flanges of the pair of first support beams and slidable attached to the second flanges of the pair of first support beams.
In some configurations of the furniture member of the above paragraph, at least one of the seatback and the seat bottom are formed from a metal material.
In some configurations of the furniture member of any one or more of the above paragraphs, the metal material is steel.
In some configurations of the furniture member of any one or more of the above paragraphs, the seatback includes a pair of support panels extending from the second panel and positioned outboard of the pair of first panels.
In some configurations of the furniture member of any one or more of the above paragraphs, the furniture member further includes a first upholstery piece disposed on the seatback and secured to the seatback using a plurality of first clips.
In some configurations of the furniture member of any one or more of the above paragraphs, the first upholstery piece is sewn onto each of the plurality of first clips.
In some configurations of the furniture member of any one or more of the above paragraphs, each of the first clips are hooked to at least one of the pair of first panels and the pair of support panels of the seatback.
In some configurations of the furniture member of any one or more of the above paragraphs, the furniture member further includes a second upholstery piece disposed on the seat bottom and secured to the seat bottom using a plurality of second clips.
In some configurations of the furniture member of any one or more of the above paragraphs, the second upholstery piece is sewn onto each of the plurality of second clips.
In some configurations of the furniture member of any one or more of the above paragraphs, each of the second clips are hooked to at least one of the pair of first support beams and the pair of second support beams of the seat bottom.
In some configurations of the furniture member of any one or more of the above paragraphs, the pair of linkages include a second link that is attached to the seatback and a first link that is pivotally attached to the second link.
In some configurations of the furniture member of any one or more of the above paragraphs, the second link is rotatably attached to the first flange of the pair of first support beams.
In some configurations of the furniture member of any one or more of the above paragraphs, the first link includes a slot and is attached to the second flange of each of the pair of first support beams using a mechanical fastener.
In some configurations of the furniture member of any one or more of the above paragraphs, the mechanical fastener is slidable within the slot as the seatback and seat bottom moves between the upright position and reclined position.
In yet another form, the present disclosure provides a furniture member that includes a seatback, a seat bottom, a seat frame, and a seat base. The seat bottom is pivotally attached to the seatback using a pair of linkages. The seat frame includes a pair of armrests that are disposed on opposing sides of the seat bottom. The seat base coupled to the seat frame using a pair of rocker spring assemblies. The seat base includes a pair of side support members that includes a top surface that is flat, and a first cross member that extends between the pair of side support members. Each of the pair of side support members are welded to the first cross member.
In some configurations of the furniture member of the above paragraph, the seat base is formed from a metal material.
In some configurations of the furniture member of any one or more of the above paragraphs, the metal material is steel.
In some configurations of the furniture member of any one or more of the above paragraphs, the seat base includes a second cross member that extends between the pair of side support members and the second cross member is spaced apart from the first cross member.
In some configurations of the furniture member of any one or more of the above paragraphs, the seat base includes a support panel that extends between the first and second cross members and extends between the pair of side support members.
In some configurations of the furniture member of any one or more of the above paragraphs, the support panel includes an opening sized to package a pair of first support links, a pair of swing links, a pair of second support links, a pair of cross links, and a pair of third support links of a legrest mechanism.
In some configurations of the furniture member of any one or more of the above paragraphs, each of the pair of side support members extends between a first end and a second end and includes a base angle rail and a base rail. The base angle rail includes the top surface and opposing sidewalls extending from the top surface. The base rail is disposed between the sidewalls of the base angle rail and extends between the first and second ends of the side support member.
In some configurations of the furniture member of any one or more of the above paragraphs, each of the side support members includes a rocker support rail and a side rail. The rocker support rail includes the top surface, an inboard wall extending from the top surface, and a bottom wall substantially parallel with the top surface. The side rail includes a base wall disposed below the bottom wall of the rocker support rail and an outboard wall extending from the base wall and substantially parallel with the inboard wall of the rocker support rail.
In yet another form, the present disclosure provides a furniture member that may include a seat base, a seat assembly, first and second rocker members, and first and second rocker spring assemblies. The seat assembly may include a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom. The seat assembly may be movable relative to the seat base between a first rocking position and a second rocking position. The first rocker member and the second rocker member may be fixedly attached to the seat frame assembly. Each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base. The first rocker spring assembly and the second rocker spring assembly are secured to the seat base and the first and second rocker members, respectively. The first rocker spring assembly includes a first mount bracket that is fixedly attached to the first rocker member, a second mount bracket that is fixedly attached to the seat base, and a first spring that extends between the first and second mount brackets, and a first tilt restricting pin movably attached to the first and second mount brackets. The second rocker spring assembly includes a third mount bracket that is fixedly attached to the second rocker member, a fourth mount bracket that is fixedly attached to the seat base, a second spring that extends between the third and fourth mount brackets, and a second tilt restricting pin movably attached to the third and fourth mount brackets. The first tilt restricting pin is offset from the first spring such that coils of the first spring do not encircle the first tilt restricting pin. The second tilt restricting pin is offset from the second spring such that coils of the second spring do not encircle the second tilt restricting pin.
In some configurations of the furniture member of the above paragraph, the first and second tilt restricting pins are tubular members.
In some configurations of the furniture member of any of the above paragraphs, each of the mount brackets include a spring support surface and apertures arranged along an axis that is angled relative to the spring support surface.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTIONExample embodiments will now be described more fully with reference to the accompanying drawings.
Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
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 may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. 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 example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
With reference to
The seat assembly 52 may move between the upright and reclined positions while the legrest mechanism 56 is in either of the extended and retracted positions and while the seat assembly 52 is in any of the nominal rocking position, forward-tilt rocking position, and the rearward-tilt rocking position. The legrest mechanism 56 may move between the extended and retracted positions while the seat assembly 52 is in any of the nominal rocking position, forward-tilt rocking position, and the rearward-tilt rocking position and in either of the upright and reclined positions. The seat assembly 52 may rock (among the nominal rocking position, forward-tilt rocking position, and the rearward-tilt rocking position) while the seat assembly 52 is in either of the upright and reclined positions and while the legrest mechanism 56 is in the retracted position. However, the seat assembly 52 is restricted from rocking (i.e., moving among the nominal, forward-tilt, and rearward-tilt rocking positions) while the legrest mechanism 56 is in the extended position. That is, when the legrest mechanism 56 is moved into the extended position, the pawl rack mechanism 58 locks the seat assembly 52 in its then-current rocking position (see
With reference to
As shown in
The seat bottom assembly 66 may include a pair of first support beams 84 and a pair of second support beams 86. Each of the first support beams 84 may be in mirror image configurations with each other and the second support beams 86 may be in mirror image configurations with each other. Each of the first support beams 84 may be attached to the pair of second support beams 86 at opposing ends of the first support beam 84 and each second support beam 86 may be attached to the pair of first support beams 84 at opposing ends of the second support beam 86. Accordingly, the pairs of first and second support beams 84, 86 may cooperate to substantially form a frame for the seat bottom assembly 66 that may support a seat cushion (not shown), seat bottom springs (not shown), and/or seat bottom slats (not shown), for example. The support beams 84, 86 could be solid beams or the support beams 84, 86 could be formed from sheets of material (e.g., metal, plastic, or composite materials) that are bent or otherwise shaped into elongated members having generally L-shaped or U-shaped profiles, for example. In some configurations, the support beams 84, 86 could be hollow or tubular members. In other configuration, the support beams 84, 86 could have other suitable cross-sectional profiles.
As shown in
As shown in
The second link 106 extends between a first link end 116 and a second link end 118 that opposes the first link end 116. The second link 106 may include a first bend 120 positioned near the first link end 116 and a second bend 122 positioned near the second link end 118. The first and second bends 120, 122 may be formed in opposite directions. As shown in
A slotted member 134 may be fixedly attached to each of the first support beams 84 of the seat bottom assembly 66 and positioned adjacent to the first end 88. More specifically, the slotted member 134 may include a first member end 136 that is secured to the first support beam 84 and a second member end 138 that is secured the first flange 92 of the first support beam 84. The slotted member 134 may include a slot 140 that is angled and extends through the slotted member 134 between the first and second member ends 136, 138.
With reference to
Upholstery may be disposed over the seat frame assembly 62, the seatback assembly 64, and the seat bottom assembly 66 and used to cover the suspension springs (not shown) and cushioning (not shown) of the seat assembly 52. With additional reference to
With additional reference to
Either or both of the seatback assembly 64 and the seat bottom assembly 66 may be formed from metal, such as steel or aluminum, for example, or any other suitable material (e.g., a composite material). Compared against wood, use of a metal material allows for significant improvements. First, availability of wood is often dependent on the harvest season for timber. The mechanical properties of wood may vary from one tree to another and from one harvest season to another, leading to inconsistency in mechanical properties. Furthermore, timing delays in the harvest seasons may significantly impact production timing of the seat assembly 52. In contrast, metal yields consistent mechanical properties and the production of metal is generally not dependent upon seasons or weather.
Additionally, compared to wood, metal allows for a more efficient process of attaching upholstery to the seatback assembly 64 and the seat bottom assembly 66. Staples are commonly used to secure upholstery to the seat assemblies formed from wood. The process of stapling upholstery to a wooden frame of a furniture member requires a large amount of skill and thus, it is very difficult to train upholsters. However, use of metal allows for utilizing the first and second clips 145, 148 to attach upholstery instead of staples. Attaching upholstery via the first and second clips 145, 148 allows for a more efficient upholstery process. More specifically, attaching upholstery via first and second clips 145, 148 does not require the immense amount of skill and thus, does not require highly trained upholsters. Furthermore, use of first and second clips 145, 148 to secure upholstery yields a more comfortable seat assembly 52 that appears more aesthetically pleasing, as compared to using staples.
With reference to
As shown in
With reference to
Each of the first and second springs 188, 189 may include a coil 196 (
Each of the first and second springs 188, 189 may extend between a first spring end 198 (i.e., a top end) and a second spring end 200 (i.e., a bottom end) that opposes the first spring end 198 (
Use of only one spring in each of the rocker spring assemblies 152, 153, as compared to two or more springs in each of the rocker spring assemblies 152, 153, reduces the number of parts used in the rocker spring assemblies 152, 153 and therefore, the cost of the rocker spring assemblies 152, 153. As will be described in greater detail below, use of one spring in each of the rocker spring assemblies 152, 153, as compared to using two or more springs in each of the rocker spring assemblies 152, 153 additionally provides an enhanced rocking performance and improved durability performance during the rocking movement among the nominal rocking position, forward-tilt rocking position and rearward-tilt rocking position and assists the furniture member 50 in achieving a zero-gravity body tilt position.
The first and second rocker spring assemblies 152, 153 may be substantially identical and configured in mirror image configurations such that the first and second springs 188 are handed springs. Therefore, the following discussion of the components of the first rocker spring assembly 152 applies equally to components of the second rocker spring assembly 153, respectively.
With continues reference to
The first mount bracket 190 may include an outboard wall 206, a base 208, and an inboard wall 210. The outboard wall 206, base 208 and inboard wall 210 cooperate to substantially form a U-shape. The outboard wall 206 may include one or more apertures 212. Mechanical fasteners 214 (
The base 208 may include a hook 218, a first raised alignment member 220, and a second raised alignment member 222 to secure the first spring 188 to the first mount bracket 190. The hook 218 may be positioned adjacent to the outboard wall 206 and may be aligned with the slot 216 such that one coil 196 of the first spring 188 may extend through the slot 216 and be retained to the first mount bracket 190 by the hook 218. Additionally, the first and second raised alignment members 220, 222 may directly contact an inner perimeter edge 224 of the first spring 188 to further secure the first spring 188 to the first or second mount brackets 190, 192. The first and second raised alignment members 220, 222 can be formed by stamping material of the base 208. The first and second raised alignment members 220, 222 are illustrated as triangular shaped, but may be formed in any suitable shape. Furthermore, the base 208 may include an aperture 225 that is positioned between the hook 218 and the slot 216 and positioned between the first and second raised alignment members 220, 222.
The first limit wire 194 may extend between a first wire end 226 and a second wire end 228 that opposes the first wire end 226. A first limit 229 may be disposed at the first wire end 226 and a second limit 230 may be disposed at the second wire end 228. In the illustrated example, the first limit 229 is formed as a rounded head and the second limit 230 is formed as a crimped flat. However, the first and second limits 229, 230 may be formed in any suitable shape or formation. The first wire end 226 may be received in the aperture 225 of the first mount bracket 190 and the second wire end 228 may be received in the aperture 225 of the second mount bracket 192. Accordingly, the first limit wire 194 may be positioned within the first spring 188 and extend through the aperture 225 of the first and second mount brackets 190, 192. A first spacer 232 may be positioned between the first limit 229 and the aperture 225 of the first mount bracket 190. A second spacer 234 may be positioned between the second limit 230 and the aperture 225 of the second mount bracket 192. In some configurations, an internal spacer (not shown) may be positioned between the base 208 of the first mount bracket 190 and the base 208 of the second mount bracket 192 and extend annularly about the first limit wire 194. The internal spacer separates the first and second mount brackets 190, 192 to the correct dimensions without the need for a spring spreading tool.
In some configurations, a tensioning force of the first spring 188 may be adjusted to provide an increased or decreased biasing effect in a forward and/or rearward rocking direction. To accomplish this, the mounting location of the first mount bracket 190 to the first rocker member 150 may be adjusted relative to the mounting location of the second mount bracket 192 to the seat base 60, or vice versa. For example, the relative alignment of the first mount bracket 190 may be vertically and/or horizontally modified relative to the second mount bracket 192. The relative position of the first mount bracket 190 may also be angled with respect to the second mount bracket 192.
With reference to
The drive rod 250 may be rotatably supported by the seat frame assembly 62. The first and second rod ends 256, 258 of the drive rod 250 may be received in the respective side support panel 72 of the seat frame assembly 62. A support cap 261 may be positioned at the first rod end 256 and received in the respective side support panel 72. The support cap 261 may be fixed relative to the drive rod 250, and rotatable relative to the respective side support panel 72 in order to support the drive rod 250 during rotation. Additionally, the drive rod 250 may be supported by a brace member 262. The brace member 262 includes a first member end 264 and a second member end 266 that opposes the first member end 264. The first member end 264 of the brace member 262 may be fixedly attach to the front support panel 74 of the seat frame assembly 62 (
As shown in
A connecting bracket 274 may be disposed at the second rod end 272 of the support rod 252. The connecting bracket 274 may include a first wall 276, a second wall 278, and a third wall 280 that cooperate to substantially form a U-shape. The first wall 276 may be secured to the side support panel 72 that receives the second rod end 272 of the support rod 252. The second wall 278 may extend from the first wall 276 and may be secured to the front support panel 74. The third wall 280 may extend from the second wall 278 and away from the front support panel 74. In other words, the first and third walls 276, 280 may extend from opposing ends of the second wall 278. An aperture 281 may be disposed through the third wall 280 and may be aligned with the support rod 252. The connecting bracket 274 receives the support rod 252 via the aperture 281. Furthermore, the support rod 252 may be coupled to the brace member 262. The brace member 262 may include a recess 282 that is positioned adjacent to the first member end 264. The recess 282 may be aligned with the support rod 252 such that the recess 282 receives the support rod 252. Accordingly, the support rod 252 may be attached to the side support panels 72 and the front support panel 74.
The pair of drive links 284, the pair of stop members 286, and the pair of pantograph linkages 288 are disposed at opposing ends of the legrest platform 290. As will be described in greater detail below, rotation of the drive rod 250 causes the pantograph linkages 288 to move between the retracted position (
The pair of drive link 284 may be positioned at the first rod end 256 and the second rod end 258 of the drive rod 250. As shown in
Each stop member 286 may be attached to the respective drive link 284 and the pantograph linkage 288. Each stop member 286 may include a first member end 302 and a second member end 304 that opposes the first member end 302. The first member end 302 may include a pair of prongs 305 that sandwich the drive link 284 between the first and third apertures 297, 299 of the third wall 294. The second member end 304 may be positioned adjacent to the distal end 296 of the third wall 294 of the drive link 284. The second member end 304 may function as a hard stop to limit rotation of the pantograph linkages 288 as the legrest mechanism 56 moves between the first legrest position and the second legrest position. The stop member 286 may include a protrusion (not shown) that is received within the third aperture 299 of the drive link 284. Accordingly, the stop member 286 is fixedly attached to the drive link 284.
As shown in
With reference to
As shown in
The one or more plate 358 may extend between a first side 378 and a second side 380. The first side 378 of the plate 358 may be formed in a curved-like shape and may include a plurality of teeth 382. The plurality of teeth 382 are positioned adjacent to each other and may each have a depth or width W. In the illustrated example, the plurality of teeth 382 includes eighteen teeth that are each positioned adjacent to each other. However, the number of teeth 382 may be greater or less than eighteen. The second side 380 of the plate 358 may include a protrusion 384. The plates 358 may be received within the bracket 356. More specifically, the second side 380 of the plates 358 may abut the back wall 366 of the bracket 356 and the protrusion 384 may be positioned within the slot 370 in a slip-fit arrangement. The plates 358 may be secured to the bracket 356 via a pair of mechanical fasteners 386 (e.g., bolts, screws, rivets, pins, etc.) that extends through the one or more plates 358 and the pair of side walls 368. Accordingly, removal of the mechanical fasteners 386 allows for an easy removal of the plates 358 from the bracket 356, for example, in servicing the plates 358. In the illustrated example, three plates 358 are stacked and positioned within the bracket 356 such that the plurality of teeth 382 of each plate 358 are aligned. However, a greater or less number than three plates 358 may be stacked and positioned within the bracket 356. The plates 358 may be formed from a metal material (e.g., steel), a plastic material, a composite material, or any other suitable material. In one example, the plates 358 may be formed of a hardened metal material, such as hardened steel. The hardened metal material may be formed by heat treating (e.g., tempering) the metal material. The hardened metal material may provide improved wear resistance, as compared to a metal material that is not hardened.
With reference to
The spring 392 may include a first wall 410 and a second wall 412 that extends from the first wall 410 to substantially form an L-shape. The first wall 410 is attached to the pawl 394 and resiliently flexes as relative to the second wall 412 as the pawl 394 moves between the disengaged position (
The pawl 394 may include a first wall 422, a second wall 424, and a third wall 426. The first wall 422 abuts the first wall 410 of the spring 392. The first wall 422 may extend between a first wall end 428 and a second wall end 430 that opposes the first wall end 428. The first wall 422 may include a first hook 432, a first slot 434, and a second hook 436. The first hook 432 may be formed within the first wall 422 and be positioned adjacent to the first wall end 428. The first slot 434 may extend through the first wall 422 and may be positioned adjacent to the second wall end 430. The first slot 434 of the pawl 394 may be at least partially aligned with the second slot 416 of the spring 392. The second hook 436 may be positioned between the first hook 432 and the first slot 434. The second hook 436 may extend from a first surface 438 of the pawl 394 and may be directed toward the second wall 412 of the spring 392. The first slot 414 of the spring 392 may receive the second hook 436 such that the second hook 436 retains the first wall 410 of the spring 392.
The second wall 424 may extend from the first wall end 428 of the first wall 422 and may include an aperture 440. The second wall 424 may be angled such that the second wall 424 may be received within one of the plurality of teeth 382 of the rack assembly 350. The third wall 426 may extend from the second wall end 430 of the first wall 422 and more specifically, the third wall 426 may be substantially perpendicular to the first wall 422. The third wall 426 may abut the second wall 400 of the pawl mount bracket 390. Additionally, the third wall 426 may include a second slot 442 that may receive the first wall 422 of the pawl mount bracket 390. A mechanical fastener 444 (e.g., bolt, screw, rivet, pin, etc.) may extend through the first aperture 402 of the first wall 398 of the pawl mount bracket 390, the first slot 434 of the pawl 394, and the second slot 416 of the spring 392. Accordingly, removal of the mechanical fastener 444 allows for easy separation of the pawl 394 from the seat base 60 for example, to service the pawl assembly 352.
The pawl cap 396 may be secured to the pawl 394, and more specifically, to the first surface 438 of the pawl 394. The pawl cap 396 includes a first wall 446 and a second wall 448 that extends from the first wall 446. The first wall 446 of the pawl cap 396 may be secured to the first wall 422 of the pawl 394 and the second wall 448 of the pawl cap 396 may be secured to the second wall 424 of the pawl 394. The second wall 448 of the pawl cap 396 may be angled to abut the second wall 424 of the pawl 394. The pawl cap 396 may include a pair of flanges 450 disposed at opposing lateral sides of the first wall 446 and a third flange 452 extending from the second wall 448. The pair of flanges 450 may abut the pawl 394 at their respective sides. The third flange 452 may abut a top end 454 of the second wall 424 of the pawl 394. The third flange 452 may have a depth or width W1. In some examples, the width W1 of the pawl cap 396 may be the same or less than the width W of the teeth 382 of the rack assembly 350 to achieve optimal contact between the rack assembly 350 and the pawl assembly 352. Additionally, the second wall 448 of the pawl cap 396 may include an aperture 456 that is aligned with the aperture 440 of the pawl 394. A mechanical fastener 458 (e.g., bolt, screw, rivet, pin, etc.) may extend through the apertures 440, 456 to secure the pawl cap 396 to the pawl 394. The mechanical fastener 458 may be positioned near the third flange 452 to help minimize flexing of the pawl cap 396 during movement of the pawl assembly 352. The pawl cap 396 may be relatively thin to reduce the amount of material use, and therefore, the cost to manufacture the pawl cap 396.
The pawl cap 396 may be formed from a metal material (e.g., steel), a plastic material, a composite material, or any other suitable material. Use of the pawl cap 396 protects the pawl 394 from wearing. Furthermore, use of the pawl cap 396 results in a reduced effort to release the pawl assembly 352 from the rack assembly 350 when moving the pawl assembly 352 between the disengaged position (
Returning to
As shown in
While the seat base 60, seatback assembly 64, seat bottom assembly 66, plates 358 of the rack assembly 350, and pawl cap 396 of the pawl assembly 352, are described above as being formed from metal, in some configurations, any or all of the seat base 60, seatback assembly 64, seat bottom assembly 66, plates 358 and pawl cap 396 could be formed from wood or other suitable materials.
With reference to
As shown in
To move the seat assembly 52 from the reclined position (
In some configurations, the furniture member 50 may include an electric actuator (e.g., a motor) and a user control (e.g., switches, knobs, and/or buttons). The occupant of the furniture member 50 may operate the user control to cause the electric actuator to move the seat assembly 52 to the upright or reclined positions or any position in between.
As shown in
Rotation of the drive rod 250 in the rearward direction simultaneously rotates the drive link 284 of the legrest mechanism 56 since the drive rod 250 is fixedly received within the first and third walls 292, 294 of the drive link 284. Simultaneously, rotation of the drive link 284 rotates the stop member 286 and the first support link 306 of the pantograph linkages 288 in a corresponding direction. Rotation of the first support link 306 rotates the swing link 308 and the cross link 312. Simultaneously, rotation of the swing link 308 and the cross link 312 causes the second support link 310 to rotate. Additionally, rotation of the cross link 312 rotates the third support link 314. In response, rotation of the second support link 310 and the third support link 314 rotates the bracket link 316 to place the legrest mechanism 56 into the extended position. Thereby, the legrest platform 290 extends so that the occupant may rest his or her legs and/or feet upon the legrest platform.
As shown in
Returning to
To move the legrest mechanism 56 from the extended position to the retracted position, the occupant of the furniture member 50 may activate (i.e., rotate) the release lever 260 in a forward direction (i.e., second direction). Activation of the release lever 260 simultaneously rotates the drive rod 250 in a corresponding direction. Rotation of the drive rod 250 simultaneously rotates the drive link 284 of the legrest mechanism 56 since the drive rod 250 is fixedly received within the first and third walls 292, 294 of the drive link 284. Rotation of the drive link 284 thereby rotates the stop member 286 and the first support link 306 of the pantograph linkages 288 in a corresponding direction. Rotation of the first support link 306 thereby, rotates the remaining links 308, 310, 312, 314, 316 of the pantograph linkages 288 at their respective attachments to move the legrest mechanism 56 into the retracted position.
Additionally, activation (i.e., rotation) of the release lever 260 in the forward direction correspondingly rotates the crank link 462 as the drive rod 250 is fixedly received within the crank link 462. Rotation of the crank link 462 simultaneously drives the actuation link 460 to move rearward, and in response, moves the pawl assembly 352 from the engaged position (
As shown in
With reference to
To move the furniture member 50 from the nominal rocking position (
When the seat assembly 52 is in the forward-tilt rocking position (or any other rocking position), the occupant may activate the release lever 260 to place the legrest mechanism 56 in the extended position, as shown in
To move the seat assembly 52 from the nominal rocking position to the rearward-tilt rocking position (i.e., while the pawl assembly 352 is in the disengaged position), the occupant may apply a rearward force against the seatback assembly 64. In response, the first and second rocker members 150, 151 rocks rearward along the flat surface 172 of the respective side support member 154 of the seat base 60. Simultaneously, the first and third mount brackets 190, 191 rotates rearward relative to the second and fourth mount bracket 192, 193, causing the first and second springs 188, 189 to bend in a rearward direction (
When the seat assembly 52 is in the rearward-tilt rocking position, the occupant may activate the release lever 260 to place the legrest mechanism 56 in the extended position, as shown in
The zero-gravity body tilt position is achievable substantially because of the single springs 188, 189 of the first and second rocker spring assemblies 152, 153 and the positioning of the teeth 382 of the rack assembly 350. Use of one spring 188, 189 in each rocker spring assembly 152, 153, as compared to two or more springs in each rocker spring assembly 152, 153, allows the springs 188, 189 to be positioned substantially equidistantly between front and rear ends of the respective mount brackets 190, 191, 192, 193. Accordingly, the first and second springs 188 do not require a significant amount of stretch as the seat assembly 52 moves from the nominal rocking position to the rearward-tilt rocking position, allowing for improved durability performance of the first and second rocker spring assemblies 152, 153 and a greater rearward-tilt as compared to when two or more springs are included in each of the rocker spring assemblies 152, 153.
With reference to
Each side support member 1154 includes a base rail 1512 and a base angle rail 1514. The base rail 1512 extends between a first rail end 1516 and a second rail end 1518 that opposes the first rail end 1516. The base rail 1512 may have a square cross-sectional shape with an internal cavity (not shown). A push end cap 1522 may be disposed at each of the first and second rail ends 1516, 1518 of the base rail 1512 to close the internal cavity. A base glide 1524 may be disposed below the base rail 1512 at each of the first and second rail ends 1516, 1518 of the base rail 1512.
The base angle rail 1514 may be disposed on top of the base rail 1512 and positioned near the first rail end 1516 of the base rail 1512. The base angle rail 1514 may extend between a first rail end 1526 and a second rail end 1528 that opposes the first rail end 1526. The base angle rail 1514 may include an outboard rail wall 1532, a top rail wall 1534, and an inboard rail wall 1536 that opposes the outboard rail wall 1532. The outboard, top, and inboard rail walls 1532, 1534, 1536 cooperate to substantially form a U-shape and may be formed as a single component. The base rail 1512 may be positioned between the outboard and inboard rail walls 1532, 1536 and the top rail wall 1534 may be positioned above the base rail 1512. The first rail end 1526 of the base angle rail 1514 may be positioned adjacent to the first rail end 1516 of the base rail 1512. The second rail end 1528 of the base angle rail 1514 may be positioned between the first and second rail ends 1516, 1518 of the base rail 1512.
Furthermore, the top rail wall 1534 may have a flat surface 1538 and an angled surface 1540. The flat surface 1538 may extend from the angled surface 1540 to the second rail end 1528 of the base angle rail 1514. Additionally, the inboard rail wall 1536 may include one or more apertures 1544 that are configured to receive the mechanical fasteners 214 (
The first cross member 1156 may be disposed between the first rail ends 1526 of the base angle rails 1514 and the second cross member 1158 may be disposed between the second rail ends 1528 of the base angle rails 1514. The support panel 1510 may be disposed between the first and second cross members 1156, 1158, and between the pair of side support members 1154. In the illustrated example, the first cross member 1156, second cross member 1158 and support panel 1510 may be formed as a single component. However, the first cross member 1156, second cross member 1158 and support panel 1510 may be formed as separate components. The support panel 1510 may include an opening 1546.
The opening 1546 may be formed by cutting a panel 1547 (e.g., a sheet or plate of material) from the support panel 1510. In some examples, the removed panel 1547 may be discarded as scrap material. However, the removed sheet may be used to create the links of the pantograph linkages 288 (
The side support member 2154 may extend between a first rail end 2516 and a second rail end 2518 that opposes the first rail end 2516. A base glide 2524 may be disposed below the pair of side support members 2154 at each of the first and second rail ends 2516, 2518. Each side support member 2154 may include a base rail 2512 and a base angle rail 2514 disposed on top of the base rail 2512. The base angle rail 2514 may include an outboard rail wall 2532, a top rail wall 2534, and an inboard rail wall 2536. The outboard rail wall 2532, top rail wall 2534, and inboard rail wall 2536 may cooperate to substantially form a U-shape. The base rail 2512 may be positioned between the outboard and inboard rail walls 2532, 2536 and the top rail wall 2534 may be positioned above the base rail 2512. Accordingly, the base rail 2512 and the base angle rail 2514 may define an internal cavity 2521 disposed between the base rail 2512 and the base angle rail 2514. A push end cap 2522 may be disposed at each of the second rail ends 2518 of the side support members 2154 to close the internal cavity 2521. The first rail ends 2516 ends may remain open to the internal cavity 2521.
The top rail wall 2534 may have a flat surface 2538 and an angled surface 2540. The flat surface 2538 may be positioned near the first rail end 2516 and the angled surface 2540 may be positioned at the second rail end 2518. The inboard rail wall 2536 may include one or more apertures 2544 that are configured to receive the mechanical fasteners 214 (
The side support members 2154, first cross member 2156, second cross member 2158, and support panel 2510 are composed of wood, metal material (e.g., aluminum or steel), plastic, a composite material, or any other suitable material. The side support members 2154, the first and second cross members 2156, 2158 and support panel 2510 may be fixed relative to each other, such as by methods of welding. In other words, the seat base 2060 may be a stationary base frame for the furniture member 50.
With reference to
The side support members 3154 may include a base rail 3512 and a base angle rail 3514. The base rail 3512 may extend between a first rail end 3516 and a second rail end 3518 and the base angle rail 3514 may extend between a first rail end 3526 and a second rail end 3528. The base angle rail 3514 may include an outboard rail wall 3532, a top rail wall 3534, and an inboard rail wall 3536.
The first cross member 3156 may disposed between the first rail ends 3526 of the base angle rails 3514. A flange 3548 may extend longitudinally from the first cross member 3156. The flange 3548 may extend laterally below the base rails 3512 to the outboard rail walls 3532 of the base angle rails 3514. The second cross member 3158 may be disposed between the outboard rail walls 3532 of the base angle rails 3514 and may be positioned at the second rail ends 3528 of the base angle rails 3514. More specifically, the second cross member 3158 may include a first wall 3550 and a second wall 3552 that cooperate to substantially form an L-shape. The first wall 3550 of the second cross member 3158 may be positioned in a substantially vertical orientation and may extend through the inboard rail walls 3536 of the base angle rails 3514 to the outboard rail wall 3532. The second wall 3552 of the second cross member 3158 may be positioned in a substantially horizontal oriental and may extend below the base rails 3512 to the outboard rail walls 3532 of the base angle rails 3514.
The side support members 3154, first cross member 3156, and second cross member 3158 are composed of wood, metal material (e.g., aluminum or steel), plastic, a composite material, or any other suitable material. The side support members 3154 and the first and second cross members 3156, 3158 may be fixed relative to each other, such as by methods of welding. In other words, the seat base 3060 may be a stationary base frame for the furniture member 50.
With reference to
The side support members 4154 may include a base rail 4512 and a base angle rail 4514. The base rail 4512 may extend between a first rail end 4516 and a second rail end 4518 and the base angle rail 4514 may extend between a first rail end 4526 and a second rail end 4528. The base angle rail 4514 may include an outboard rail wall 4532, a top rail wall 4534, and an inboard rail wall 4536.
The first cross member 4156 may extend between the inboard rail walls 4536 and may be positioned at the first rail end 4526 of the base angle rail 4514. The first cross member 4156 may be positioned in substantially horizontal orientation. The second cross member 4158 may extend between the inboard rail walls 4536 and may be positioned at the second rail end 4528 of the base angle rail 4514. The second cross members 4158 may be positioned in a substantially vertical orientation. A pair of brackets 4553 may extend between the first and second cross members 4156, 4158 and may be secured to the first and second cross member 4156, 4158. The pair of brackets 4553 are spaced apart such that one bracket 4553 is positioned adjacent to one side support member 4154 and the other bracket 4553 is positioned adjacent to the other side support member 4154. More specifically, the brackets 4553 abut the inboard rail walls 4536 of the base angle rail 4514. Mechanical fasteners 4554 may be used to secure each bracket 4553 to the first cross member 4156 and mechanical fasteners 4555 may be used to secure each bracket 4553 to the second cross member 4158.
The side support members 4154, first cross member 4156, second cross member 4158, and brackets 4553 are composed of wood, metal material (e.g., aluminum or steel), plastic, a composite material, or any other suitable material. The side support members 4154 and the first and second cross members 4156, 4158 may be fixed relative to each other, such as by methods of welding. In other words, the seat base 4060 may be a stationary base frame for the furniture member 50.
The rocker support rail 5558 may include a first rail end 5568 and a second rail end 5570 that opposes the first rail end 5568. The rocker support rail 5558 may include a top wall 5572 that is flat, an inboard wall 5574, and a bottom wall 5576 that cooperate to form a U-shape. The top wall 5572 of the rocker support rail 5558 may be attached to the outboard wall 5564 and the bottom wall 5576 of the rocker support rail 5558 abuts the base wall 5566. Accordingly, the inboard wall 5574 of the rocker support rail 5558 extends between the top and bottom walls 5572, 5576 and opposes the outboard wall 5564 of the side rail 5556. A set of mechanical fasteners 5578 extend through the inboard wall 5574 and the outboard wall 5564 to secure the side rail 5556 to the rocker support rail 5558. Accordingly, an internal cavity 5580 is defined between the side rail 5556 and the rocker support rail 5558.
A connector (not shown) may be attached to the inboard wall 5574 and positioned adjacent to the first rail end 5568 of the rocker support rail 5558. Additionally, the inboard wall 5574 may include one or more apertures 5544 that are configured to receive mechanical fastener 214 (
The first cross member 5156 may extend between the inboard walls 5574 of the pair of rocker support rails 5558 and may be positioned at the first rail end 5568 of the rocker support rail 5558. More specifically, mechanical fasteners 5582 may secure the first cross member 5156 to the connector, and thereby to the rocker support rail 5558. The second cross member 5158 may extend between the outboard walls 5564 of the pair of side rails 5556 and may be positioned at the second rail end 5570 of the rocker support rail 5558. More specifically, the second cross member 5158 may include a first wall 5550 and a second wall 5552 that cooperate to substantially form an L-shape. The first wall 5550 may extend beside the second rail end 5570 of the rocker support rail 5558 to the outboard wall 5564 of the side rail 5556. The second wall 5552 may extend below the rocker support rails 5558 and to the outboard wall 5564 of the side rail 5556.
The side support members 5154, first cross member 5156, and second cross member 5158 are composed of wood, metal material (e.g., aluminum or steel), plastic, a composite material, or any other suitable material. The side support members 5154 and the second cross member 5158 may be attached using methods of welding. The side support members 5154 and the first and second cross members 5156, 5158 may be fixed relative to each other. In other words, the seat base 5060 may be a stationary base frame for the furniture member 50.
The pantograph linkage 6288 may additionally include a mid-ottoman bracket 6584 that supports a mid-ottoman platform (not shown). The mid-ottoman bracket 6584 may be substantially formed in an L-shape. The mid-ottoman bracket 6584 may include a first end 6586 and a second end 6588. The first end 6586 may be attached to the cross link 6312 using a mechanical fastener 6590. Additionally, a first flange 6592 may extend from the first end 6586 and wrap around a lateral edge 6594 of the cross link 6312 for additional support. A second flange 6596 may extend from the second end 6588 in a substantially perpendicular direction. The second flange 6596 may be attached to the mid-ottoman platform.
With reference to
The ratchet rack 8602 may include a first side 8610 that is positioned distal from the bracket 8600 and a second side 8612 that is received in the bracket 8600. The pin 8608 may extend through the second side 8612 to attach the ratchet rack 8602 to the bracket 8600. A cap nut 8614 or a push nut may be pressed onto the end of the pin 8608 to prevent the pin 8608 from unintentionally sliding out of the ratchet rack 8602. The first side 8610 may be formed in a curved-like shape and may include a plurality of teeth 8382. The plurality of teeth 8382 may be positioned adjacent to each other and may each have a depth or width W8. In the illustrated example, the plurality of teeth 8382 may include eighteen teeth 8382. However, the number of teeth 8382 may be greater than eighteen or less than eighteen.
In some configurations, the bracket 8600 may be formed from a metal material (e.g., steel) and the ratchet rack 8602 may be formed from a polymeric or elastomeric material. The polymeric or elastomeric material of the ratchet rack 8602 can reduce the noise associated with contact and friction between the pawl assembly 352 (
With reference to
The pawl mount bracket 9390 may include a first wall 9398 having a first aperture 9402 and a second wall 9400 having at least one second aperture 9404 and a hook 9406. The spring may include a first wall 9410 having a first slot 9414 and a second slot 9416 and a second wall 9412 having a third slot 9418 and at least one aperture 9420.
The pawl 9394 may include a first wall 9422, a second wall 9424, and a third wall 9426. Additionally, the pawl may include a first surface 9438 and a second surface 9439 that opposes the first surface 9438. The first wall 9422 may extend between a first wall end 9428 and a second wall end 9430 that opposes the first wall end 9428. The first wall 9422 may include a first hook 9432, a first slot 9434, and a second hook 9436. The first hook 9432 may be formed within the first wall 9422 and be positioned adjacent to the first wall end 9428. The first slot 9434 may extend through the first wall 9422 and may be positioned adjacent to the second wall end 9430. The first slot 9434 of the pawl 9394 may be at least partially aligned with the second slot 9416 of the spring 9392. The second hook 9436 may be positioned between the first hook 9432 and the first slot 9434. The second hook 9436 may extend from the first surface 9438 of the pawl 9394 and may be directed toward the second wall end 9430 of the first wall 9422. The first slot 9414 of the spring 9392 may receive the second hook 9436 of the pawl 9394 such that the second hook 9436 retains the first wall 9422 of the spring 9392.
The second wall 9424 may extend from the first wall end 9428 of the first wall 9422 and may include a protrusion 9440 that extends from the second surface 9439 of the pawl 9394. The second wall 9424 may be angled relative to the first wall 9422. The third wall 9426 may extend from the second wall end 9430 of the first wall 9422 and more specifically, the third wall 9426 may be substantially perpendicular to the first wall 9422. The third wall 9426 may include a second slot 9442 that may receive the first wall 9422 of the pawl mount bracket 9390. A mechanical fastener 9444 (e.g., bolt, screw, rivet, pin, etc.) may extend through the first aperture 9402 of the first wall 9398 of the pawl mount bracket 9390, the first slot 9414 of the pawl 9394, and the second slot 9416 of the spring 9392.
The pawl cap 9396 may be secured to the pawl 9394, and more specifically, secured to the second wall 9424 of the pawl 9394 in a slip-fit arrangement. The pawl cap 9396 may be positioned to cover a top end 9454 of the second wall 9424. The pawl cap 9396 may include a first wall 9472, a top wall 9474, and a second wall 9476. The first wall 9472 of the pawl cap 9396 abuts the first surface 9438 at the second wall 9424, the second wall 9476 of the pawl cap 9396 abuts the second surface 9439 at the second wall 9424 and the top wall 9474 of the pawl cap 9396 abuts the top end 9454 of the second wall 9424. The first wall 9472 may receive the protrusion 9440 to secure the pawl cap 9396 to the pawl 9394. The top wall 9474 of the pawl cap 9396 may have a depth or width W9. The second wall 9476 of the pawl cap 9396 includes a recess 9478 that is aligned with the protrusion 9440 of the second wall 9424. The pawl cap 9396 may be composed of a polymeric material (e.g., nylon or acetal), an elastomeric material, a composite material, or any other suitable material.
With reference to
The pawl 10394 may be made of a hardened metal material, such as hardened steel, or any other suitable material. The hardened metal material may be formed by heat treating (e.g., tempering) a metal material. The hardened metal material may provide improved wear resistance, as compared to a metal material that is not hardened.
In some configurations of the furniture member 50, a furniture member may be composed of any combinations of the alternative components described above and shown in
Referring now to
Each of the rocker spring assemblies 552 may include a spring 588, a first mount bracket 590, a second mount bracket 592, and a tilt restricting pin 594. In the configuration shown in
In some configurations, the springs 588 used in each of the rocker spring assemblies 552 are identical to each other. That is, the springs 588 of the two rocker spring assemblies 552 have the same handedness (as opposed to the spring of one of the rocker spring assemblies 552 being a left-handed spring and the spring of the other of the rocker spring assemblies 552 being a right-handed spring). Use of identical springs 588 in both of the two rocker spring assemblies 552 reduces the number of unique components in the furniture member 50 and eliminates the possibility that the wrong spring could be accidentally installed in the wrong one of the rocker spring assemblies 552 during assembly.
In some configurations, the spring 588 may be formed from music wire (e.g., instead of lower cost hard drawn wire). Forming the spring 588 from music wire allows the spring 588 to be shorter and lighter and allows for the simple shape of the mount brackets 590, 592.
The first mount bracket 590 may be fixedly attached to the respective of the rocker members 150, 151 (e.g., to the inboard surface 184 of the respective rocker member 150, 151) or to the seat frame assembly 62 (e.g., the side support panel 72). The second mount bracket 592 may be fixedly attached to the seat base 60 (e.g., to the inboard surface 168 of the respective side support member 154 of the seat base 60). The spring 588 may be disposed between and attached to the first and second mount brackets 590, 592. More specifically, an upper end of the spring 588 may be coupled to the first mount bracket 590 and a lower end of the spring 588 may be coupled to the second mount bracket 592. The first and second mount brackets 590, 592 may be substantially identical to each other and positioned in a mirror image arrangement (i.e., the second mount bracket 592 is identical to the first mount bracket 590 but is positioned upside down relative to the first mount bracket 590). Therefore, the following discussion of the first mount bracket 590 applies equally to the second mount bracket 592.
The first mount bracket 590 may include an outboard wall 606, a base (or spring support surface) 608, and an inboard wall 610. The outboard wall 606, spring support surface 608 and inboard wall 610 cooperate to substantially form a U-shape. The outboard wall 606 may include one or more apertures 612. Mechanical fasteners may extend through each of the apertures 612 of the outboard wall 606 to secure the first mount bracket 590 to the respective rocker member 150, 151 and the second mount bracket 592 to the seat base 60. An opening 616 may extend through the inboard wall 610 and/or the spring support surface 608 at or near a location where the inboard wall 610 meets the spring support surface 608. A portion of the spring 588 may extend through the opening 616.
As shown in
When attached to the spring support surface 608, the rotational axis of the coils of the spring 588 will not be perpendicular to the spring support surface 608 due to the spiraling shape of spring 588. Without correction, if the same spring 588 is applied to both sides of the furniture member 50, it would produce a slight twisting effect on the seat assembly 52 (i.e., the spring on one side of the seat assembly 52 would lean forward, and the spring on the other side of the seat assembly 52 would lean toward the rearward. The tilted orientation of the mount brackets 590, 592 (due to the angled orientation of the apertures 612 described above) may minimize or eliminate this misalignment and twisting effect and may also reduce stresses at or near the bends of the mount bracket 590.
The spring support surface 608 may include a hook 618 (
The tilt restricting pin 594 may be a tubular member having flared (or swaged) ends 620. Forming the tilt restricting pin 594 from plastic may help to reduce noise caused by friction between the tilt restricting pin 594 and the mount brackets 590, 592 during rocking. The tilt restricting pin 594 may be movably received in apertures 622 formed in the mount brackets 590, 592. Each of the mount brackets 590, 592 includes two apertures 622 that are formed on either side of the spring 588 (i.e., the spring 588 is disposed between the apertures 622 of the first mount bracket 590 and between the apertures 622 of the second mount bracket 592). As shown in
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Claims
1.-30. (canceled)
31. A furniture member comprising:
- a seat base;
- a seat assembly having a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom, wherein the seat assembly is movable relative to the seat base between a first rocking position and a second rocking position;
- a first rocker member and a second rocker member fixedly attached to the seat frame assembly, wherein each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base; and
- a first rocker spring assembly secured to the seat base and the first rocker member, wherein the first rocker spring assembly includes a first spring, and wherein the first spring is the only spring of the first rocker spring assembly;
- a second rocker spring assembly secured to the seat base and the second rocker member, wherein the second rocker spring assembly includes a second spring, and wherein the second spring is the only spring of the second rocker spring assembly;
- a rack assembly including a first side that is fixedly attached to the seat frame assembly and a second side that includes a plurality of teeth; and
- a pawl assembly movable between an engaged position and a disengaged position, and including: a pawl, a pawl cap disposed at a top end of the pawl, a mount bracket attached to the seat base, and a spring including a first wall that abuts the pawl and a second wall that abuts the mount bracket, the spring being movable between a first position and a second position.
32. The furniture member of claim 31, wherein when the pawl assembly is in the disengaged position, the seat assembly is movable between the first rocking position and the second rocking position.
33. The furniture member of claim 31, wherein when the pawl assembly is in the engaged position, the seat assembly is restricted from movement between the first rocking position and the second rocking position.
34. The furniture member of claim 33, wherein the pawl cap abuts one of the plurality of teeth of the rack assembly.
35. The furniture member of claim 31, wherein the pawl cap covers the top end of the pawl.
36. The furniture member of claim 31, wherein the pawl cap is formed from a polymeric material or an elastomeric material.
37. The furniture member of claim 31, wherein the rack assembly includes a bracket and a ratchet rack that is received in the bracket.
38. The furniture member of claim 37, wherein the ratchet rack is formed from a polymeric or an elastomeric material.
39. The furniture member of claim 37, wherein the ratchet rack is formed from the same material as the pawl cap.
40. The furniture member of claim 31, wherein the first spring is a left-handed spring, and wherein the second spring is a right-handed spring.
41. The furniture member of claim 31, wherein the first spring and the second spring have the same handedness.
42. The furniture member of claim 41, wherein each of the rocker spring assemblies includes a first mount bracket, a second mount bracket, and a tilt restricting pin, wherein the first spring of the first rocker spring assembly is attached to the first mount bracket and the second mount bracket of the first rocker spring assembly, wherein the second spring of the second rocker spring assembly is attached to the first mount bracket and the second mount bracket of the second rocker spring assembly, and wherein each of the first and second mount brackets include a spring support surface and apertures arranged along an axis that is angled relative to the spring support surface.
43. The furniture member of claim 41, wherein the tilt restricting pin is a tubular member and is offset from the respective one of the first and second springs such that coils of the first and second springs do not encircle the tilt restricting pin.
44.-73. (canceled)
74. A furniture member comprising:
- a seat base;
- a seat assembly having a seat frame assembly, a seat bottom attached to the seat frame assembly, and a seatback attached to the seat bottom, wherein the seat assembly is movable relative to the seat base between a first rocking position and a second rocking position;
- a first rocker member and a second rocker member fixedly attached to the seat frame assembly, wherein each of the first and second rocker members includes a curved bottom surface in rolling contact with a surface of the seat base; and
- a first rocker spring assembly and a second rocker spring assembly secured to the seat base and the first and second rocker members, respectively,
- wherein the first rocker spring assembly includes a first mount bracket that is fixedly attached to the first rocker member, a second mount bracket that is fixedly attached to the seat base, and a first spring that extends between the first and second mount brackets, and a first tilt restricting pin movably attached to the first and second mount brackets,
- wherein the second rocker spring assembly includes a third mount bracket that is fixedly attached to the second rocker member, a fourth mount bracket that is fixedly attached to the seat base, a second spring that extends between the third and fourth mount brackets, and a second tilt restricting pin movably attached to the third and fourth mount brackets,
- wherein the first tilt restricting pin is offset from the first spring such that coils of the first spring do not encircle the first tilt restricting pin, and
- wherein the second tilt restricting pin is offset from the second spring such that coils of the second spring do not encircle the second tilt restricting pin.
75. The furniture member of claim 74, wherein the first and second tilt restricting pins are tubular members.
76. The furniture member of claim 75, wherein each of the mount brackets include a spring support surface and apertures arranged along an axis that is angled relative to the spring support surface.
77. The furniture member of claim 74, further comprising:
- a legrest mechanism including a legrest platform, wherein the legrest platform is movable relative to the seat base between a retracted position and an extended position;
- a rack assembly including a first side that is fixedly attached to the seat frame assembly and a second side that includes a plurality of teeth; and
- a pawl assembly movable between an engaged position and a disengaged position, and including: a pawl, a pawl cap disposed at a top end of the pawl, a mount bracket attached to the seat base, and a spring including a first wall that abuts the pawl and a second wall that abuts the mount bracket, the spring is movable relative to the mount bracket between a first position and a second position,
- wherein when the legrest platform is in the extended position, the pawl cap abuts one of the plurality of teeth and restricts the seat assembly from moving between the forward-tilt rocking position and the rearward-tilt rocking position.
78. The furniture member of claim 77, wherein the rack assembly includes a bracket disposed at the first side and a ratchet rack that is received in the bracket, wherein the ratchet rack includes a set of plates, each of the plates include the plurality of teeth and the plurality of teeth of each plate are aligned with each other.
79. The furniture member of claim 77, wherein the rack assembly includes a back wall positioned at the first side and a pair of sidewalls that extend from opposing ends of the back wall to form a U-shape, and the plurality of teeth are formed in the pair of sidewalls.
80. The furniture member of claim 77, wherein the pawl cap includes a flange that extends over the top end of the pawl.
Type: Application
Filed: Jan 25, 2024
Publication Date: Aug 1, 2024
Applicant: La-Z-Boy Incorporated (Monroe, MI)
Inventors: Larry P. LAPOINTE (Temperance, MI), Christopher A. LARSEN (Georgetown, TN)
Application Number: 18/422,698
