SEATBACK FOR AN ARTICLE OF ADJUSTABLE FURNITURE

Abstract

The invention concerns a seat back (10) for an article of adjustable furniture comprising: a frame (12), at least one movable support section (14, 80) mounted for angular adjustment with respect to the frame; cam means (64) associated with one of the frame and the movable support section, cam follower means (58) associated with the other of the frame and the movable support section; actuator means (38) for moving said cam means or cam follower means associated with the frame with respect to the frame; whereby movement of said actuator means effects relative movement of said cam means with respect to said cam follower means and said relative movement effects angular adjustment of said support section relative to the frame to alter the seat back configuration. The present invention contemplates embodiments where the support section(s) comprise(s) an adjustable head rest (14), an adjustable lumbar support (80) or both.

Claims

1. A seat back for an article of adjustable furniture, comprising: a frame; at least one movable support section mounted for angular movement with respect to the frame; cam means associated with one of the frame and the movable support section, and cam follower means associated with the other one of the frame and the movable support section; actuator means for moving said cam means or said cam follower means associated with the frame with respect to the frame; whereby movement of said actuator means effects relative movement of said cam means with respect to said cam follower means and said relative movement effects angular adjustment of said support section relative to the frame to adjust the configuration of the seat back.

2. A seat back as claimed in claim 1 wherein the cam means is associated with the movable support section and the cam follower means is associated with said frame.

3. A seat back as claimed in claim 2 wherein the cam means is fixed in relation to said at least one movable support section.

4. A seat back as claimed in claim 2 wherein said cam follower means is movably mounted on or with respect to said frame.

5. A seat back as claimed in claim 1 wherein the cam means comprises a guide ramp.

6. A seat back as claimed in claim 5 wherein the guide ramp comprises an inclined guide.

7. A seat back as claimed in claim 6 wherein the guide ramp has an angle of inclination in the range of 20 to 45 degrees, preferably 25 to 35 degrees, most preferably 30 degrees+/−1 degree.

8. A seat back as claimed in claim 6 wherein the guide ramp is linear.

9. A seat back claimed in claim 1 wherein the cam follower means is fixed in relation to a moving part of said actuator means.

10. A seat back as claimed in claim 1 wherein said actuator means comprises linear actuator means arranged to move said cam follower means in the longitudinal direction of the frame.

11. A seat back as claimed in claim 1 wherein said at least one movable support section is pivotally mounted for angular adjustment with respect to said frame.

12. A seat back as claimed in claim 1 wherein said at least one movable support section comprises an adjustable lumbar support.

13. A seat back as claimed in claim 1 wherein said at least one movable support section comprises an adjustable head rest.

14. A seat back as claimed in claim 1 wherein said at least one movable support section comprises an adjustable lumbar support and an adjustable head rest.

15. A seat back as claimed in claim 14 wherein said actuator means comprises first and second actuators, said first actuator for independent movement of said adjustable head rest, and said second actuator for independent movement of said adjustable lumbar support.

16. A seat back as claimed in claim 15 wherein said first and second actuators are arranged side by side on said seat back frame.

17. A seat back as claimed in claim 1 wherein said frame comprises first and second spaced apart parallel side frame members.

Description

[0030] Various embodiments of the present invention will now be more particularly described, by way of example only, with reference to the accompanying drawings; in which:

[0031] FIG. 1 is a perspective view from the front of a seat back frame and operating mechanism for a recliner chair having an adjustable head rest according to an embodiment of the present invention;

[0032] FIG. 2 is the same as FIG. 1, with the right hand panel of the seat back frame shown in ghost outline;

[0033] FIG. 3 is a perspective view from the rear of the seat back frame and operating mechanism of FIG. 1;

[0034] FIG. 4 is the same as FIG. 3, with the right hand panel of the seat back frame shown in ghost outline;

[0035] FIG. 5 is a rear elevation view of the seat back frame and operating mechanism of FIG. 1;

[0036] In FIGS. 1 to 5 exclusively the adjustable head rest is shown in a partially extended position;

[0037] FIG. 6 is a perspective view similar to FIG. 1, with the head rest fully retracted;

[0038] FIG. 7 is a perspective view similar to FIG. 1, with the head rest fully extended;

[0039] FIG. 8 is a perspective view from the front of a seat back frame and operating mechanism for a recliner chair having an adjustable lumbar support according to an embodiment of the present invention;

[0040] FIG. 9 is the same as FIG. 8, with the right hand panel of the seat back frame shown in ghost outline;

[0041] FIG. 10 is a perspective view from the rear of the seat back frame and operating mechanism of FIG. 8;

[0042] FIG. 11 is the same as FIG. 10, with the right hand panel of the seat back frame shown in ghost outline;

[0043] FIG. 12 is a cross-section view of the seat back frame of FIG. 8;

[0044] FIG. 13 is a perspective view of the seat back frame of FIG. 8 with various components of the lumbar support removed;

[0045] FIG. 14 is a rear elevation view of the seat back frame and operating mechanism of FIG. 8;

[0046] In FIGS. 8 to 14 exclusively, the adjustable lumbar support is shown in a partially extended position;

[0047] FIG. 15 is a perspective view similar to FIG. 8, with the lumbar support fully retracted;

[0048] FIG. 16 is a perspective view similar to FIG. 1, with the lumbar support fully extended;

[0049] FIG. 17 is a perspective view from the front of a seat back frame and operating mechanism for a recliner chair having an adjustable head rest and an adjustable lumbar support according to a further embodiment of the present invention;

[0050] FIG. 18 is a perspective view from the rear of the seat back frame and operating mechanism of FIG. 17;

[0051] FIG. 19 is a perspective view from above of the seat back frame and operating mechanism of FIG. 17;

[0052] FIG. 20 is a perspective view similar to FIG. 19, with the head rest and lumbar support fully retracted;

[0053] FIG. 21 is a front elevation view of the seat back frame of FIG. 17, with the head rest and lumbar support fully retracted;

[0054] In the drawings of FIGS. 1 to 21, same and similar reference numbers designate same and similar parts.

[0055] Referring to the drawings of FIGS. 1 to 7, a seat back 10 for a recliner chair comprises a frame 12, adjustable headrest 14 and an operating mechanism for adjusting the position of the headrest with respect to the frame. In the drawings of FIGS. 1 to 7 the headrest is shown partially deployed at an intermediate position between a fully closed position (FIG. 6) and a fully open adjusted position (FIG. 7). The adjustable headrest may be considered to be a movable support section of the seat back 10.

[0056] The frame 12, which may be considered to be a first furniture component, comprises a pair of generally planar side frame members 16, preferably of wood or fibre board construction. The side frame members are arranged on opposite lateral sides of the frame and are fixedly secured together by means of a tubular cross-member 18, preferably of metal construction, which extends horizontally between the side frame members. The cross-member is attached to the side frame members by means of respective metal mounting brackets 20. The mounting brackets are fixedly secured to the inward facing surfaces of the respective said frame members at a position approximately midway along their length. The cross-member 18 and mounting brackets 20 may be joined together by welding or other means including fixing means such as screws, fasteners or the like.

[0057] The mounting brackets 20 have a generally U-shape cross-section with respective upper and lower mounting flanges 22, 24 at the ends of the U for fixedly securing the brackets to the inward facing surfaces of the side frame members, for example by means of suitable fastening means such as screws or the like. The U-shape cross-section of the mounting brackets provides a gap between the bottom of the bracket and the respective side frame member to accommodate a mounting pin 26 of the headrest. Mounting pins 26 rotatably mount the headrest with respect to the frame, between the side frame members 16, about a pivot axis defined by the pins.

[0058] The headrest 14, which may be considered to be a second furniture component, comprises a pair of elongate side members 28, preferably of metal, disposed on opposite lateral sides of the headrest. The side frame members 28 have a generally L-shape cross-section and are fixedly secured together by means of a tubular cross-member 30, preferably of metal construction, which extends horizontally between the side frame members 28. Cross-member 30 is fixedly attached towards the lower end of the respective side frame members 28 by welding or suitable fixing means. The head rest 14 further comprises an inner frame 32 attached to the respective side frame members. The inner frame 32 comprises a pair of elongate side frame members 34 fixedly secured to the outer frame side frame members 28, and a plurality of resilient support straps 36 which extend horizontally between the side frame members 34 and secured thereto by suitable fixing means. The support straps are preferably of a webbing type material well known to those in the upholstered furniture industry.

[0059] The position of the inner frame 32 relative to the side frame members 28 is adjustable along the length of the side frame members to allow manufacturing flexibility, that is to say, when the headrest is being manufactured the inner frame may be positioned and secured at one of a number of discrete mounting positions on the side frame members 28, depending on the requirements of a particular application/design.

[0060] An electrical linear actuator 38 is provided for moving the headrest 14 with respect to the frame 12 about its pivot axis. The actuator is of a known type having a low voltage DC motor 40, a gearbox 42, mounting clevis 44, outer tube or snout 46 and extendable ram 48. The actuator 38 is fixedly secured to the cross-member 18 by means of a rigid rectangular mounting plate 50, preferably of metal construction, and first and second actuator mounting brackets 52, 54 which fixedly secure the actuator to the mounting plate. The first mounting bracket 52 secures the motor end of the actuator to the mounting plate at clevis 44. The second mounting bracket 54 secures the snout 46 of the actuator to the mounting plate at the other end of the mounting plate. The second mounting bracket clamps the snout 46 of the actuator to the mounting plate. This ensures there is no operational movement of the actuator other than the ram in use. The actuator 38 is not free to rotate on its mountings 52, 54.

[0061] The distal end of the ram is provided with a cam follower 56 in the form of two adjacent roller bearings 58 rotatably mounted on a common shaft or pin 60 secured to a clevis mounting 62 at the distal end of the ram 48. The cam follower engages a cam 64 in the form of a metal plate 66 which extends rearwards and upwards from the rear of the cross-member 30. The angle of the metal plate 66 with respect to the notional plane of the headrest 14 is determined by the amount of headrest adjustment required per unit of extension of the actuator ram. That is to say the angle of the plate 66, with respect to the plane of the headrest, determines the gearing of the actuator and operating mechanism of the headrest. A shallow angle would provide low gearing. A higher angle, but less than 90 degrees, would provide high gearing.

[0062] It is to be understood that as the actuator is extended, in use, the cam follower rollers 58 engage the under surface of the angled cam plate 66 and cause the head rest to rotate about its pivot axis form its retracted position of FIG. 6 to is fully extended position of FIG. 7. The maximum angle of adjustment of the headrest about its pivot axis is typically 25-55 degrees, for example.

[0063] It is preferred that actuator 38 is of the push only type so that a force is only generated when the actuator is extended and not when retracted. This ensures no crushing force is generated at potential entrapment points between the headrest and the frame, in use, when the actuator is retracted. This is a desirable safety feature of adjustable furniture.

[0064] The headrest is biased rearwards towards the frame by means of a spring to assist retraction of the headrest back to its stowed position, where it lies flat within the frame 12, as best seen in FIG. 6, In the present embodiment, a coil spring 68 is secured at one end to the distal end of the plate 66 and at the other to the cross-member 18. Thus, in use, when the actuator load is selectively removed to initiate retraction of the headrest, the spring 68 acts as a return spring and pulls the headrest rearwards as the ram is retracted. As there is no direct connection between the cam 64 and cam follower 56, only mutual abutting engagement, the headrest can be moved manually and freely if necessary, against the returning force of the spring 68, away from the seat back frame so that the user can clear any obstruction that may exist in the region between the headrest and seat back frame preventing retraction.

[0065] In order to limit the angular adjustment of the headrest 14 relative to the frame 12, stop means are provided in the form of lugs 70 on each of the mounting brackets 20. The lugs 70 extend perpendicularly from the mounting brackets towards the interior region of the frame 12. The lugs 70 prevent the headrest moving further rearwards when in the fully retracted position of FIG. 7 by mutual engagement with the respective side frame members 28 of the headrest.

[0066] Referring to the drawings of FIGS. 8 to 16, a seat back 10 for a recliner chair comprises a frame 12, adjustable lumbar support 80 and an operating mechanism for adjusting the position of the lumbar support with respect to the frame. In the drawings of FIGS. 8 to 16 the lumbar support is shown partially deployed at an intermediate position between a fully closed position (FIG. 13) and a fully open adjusted position (FIG. 14). The adjustable lumbar support may be considered to be a movable support section of the seat back 10.

[0067] The seat back 10 of FIGS. 8 to 16 is similar to the seat back of FIGS. 1 to 7, but modified to accommodate adjustable lumbar support 80 instead of the adjustable headrest 14, which the lumbar support 80 replaces. The adjustable lumbar support and its associated operating mechanism is an approximate mirror image/inversion of the adjustable headrest previously described, that is to say the operating mechanism is associated with and acts on an adjustable lumbar support in the lower part of the seat back frame instead of the adjustable headrest in the upper part of the seat back frame as in the previously described embodiment.

[0068] The frame 12, comprising planar side frame members 16, tubular cross-member 18 and mounting brackets 20, is the same as the embodiment of FIGS. 1 to 7.

[0069] The U-shape cross-section of the mounting brackets 20 provides a gap between the bottom of the bracket and the respective side frame member to accommodate a mounting pin 82 of the lumbar support 80. Mounting pins 82 rotatably mount the lumbar support with respect to the frame, between the side frame members 16, about a pivot axis defined by the pins 82.

[0070] The lumbar support 80, which may be considered to be a second furniture component, comprises a pair of planar elongate side members 84, preferably of metal, disposed on opposite lateral sides of the headrest.

[0071] The side frame members 84 are fixedly secured together by means of a tubular cross-member 86, preferably of metal construction, which extends horizontally between the side frame members 84. Cross-member 86 is fixedly attached towards the lower end of the respective side frame members 84 by welding or suitable fixing means. The lumbar support 80 further comprises adjustable mounting brackets 88 attached to the respective side frame members 84 and a profiled lumbar support panel 90. The lumbar support panel 90 has an approximate convex outward facing surface comprising three angular sections which are joined together and extend substantially horizontally between the side frame members 84. The lumbar support panel is connected to the side frame members by the respective adjustable mounting brackets 88.

[0072] The position of the lumbar support panel 90 relative to the side frame members 84 is adjustable along the length of the adjustable brackets to allow manufacturing flexibility, that is to say, when the lumbar support is being manufactured the mounting brackets 88 may be positioned and secured at one of a number of discrete mounting positions on the side frame members 84, as determined by registration mounting holes 92 in brackets 88, through which suitable fixing means pass to secure the mounting brackets 88 to the respective side frame members 84 at an appropriate position along the length of the brackets.

[0073] An electrical linear actuator 38′ is provided for moving the lumbar support 80 with respect to the frame 12 about its pivot axis. The actuator is of a known type having a low voltage DC motor 40, a gearbox 42, mounting clevis 44, outer tube or snout 46 and extendable ram 48. The actuator 38 is fixedly secured to the cross-member 18 by means of a rigid generally rectangular mounting plate 50′, preferably of metal construction, and first and second actuator mounting brackets 52′, 54′ which fixedly secure the actuator to the mounting plate. The first mounting bracket 52′ secures the motor end of the actuator to the mounting plate at clevis 44′. The second mounting bracket 54′ secures the snout 46 of the actuator to the mounting plate in the region adjacent the cross-member 18. The second mounting bracket clamps the snout 46 of the actuator to the mounting plate. This ensures there is no operational movement of the actuator other than the ram in use. The actuator 38 is not free to rotate on its mountings 52′, 54′.

[0074] The distal end of the ram is provided with a cam follower 56′ in the form of two adjacent roller bearings 58′ rotatably mounted on a common shaft or pin 60′ secured to a clevis mounting 62 at the distal end of the ram 48. The cam follower engages a cam 64′ in the form of a metal plate 66′ which extends downward and forwards from the front of the cross-member 86, best seen in FIG. 12. The angle of the metal plate 66′ with respect to the notional plane of the lumbar support 80 is determined by the amount of lumbar support adjustment required per unit of extension of the actuator ram. That is to say the angle of the plate 66′, with respect to the notional plane of the lumbar support, determines the gearing of the actuator and operating mechanism of the lumbar support. A shallow angle would provide low gearing. A higher angle, but less than 90 degrees, would provide high gearing.

[0075] It is to be understood that as the actuator 38′ is extended, in use, the cam follower rollers 58′ engage the forward facing surface of the angled cam plate 66′ and cause the lumbar support 80 to rotate about its pivot axis form its retracted position of FIG. 15 to is fully extended position of FIG. 16. The maximum angle of adjustment of the lumbar support about its pivot axis is typically 10-30 degrees, for example.

[0076] It is preferred that actuator 38 is of the push only type so that a force is only generated when the actuator is extended and not when retracted.

[0077] The lumbar support 80 is biased rearwards towards the frame by means of a spring to assist retraction of the lumbar support back to its stowed position, where it lies flat within the frame 12, as best seen in FIG. 15, In the present embodiment, a coil spring 68′ is secured at one end to the distal end of the plate 66′ and at the other to the cross-member 18. Thus, in use, when the actuator load is selectively removed to initiate retraction of the lumbar support 80, the spring 68′ acts as a return spring and pulls the lumbar support rearwards as the ram is retracted. There is no direct connection between the cam 64′ and cam follower 56′, only mutual abutting engagement.

[0078] In order to limit the angular adjustment of the lumbar support 14 relative to the frame 12, stop means are provided in the form of lugs 92 on each of the mounting brackets 20. The lugs 92 extend perpendicularly from the mounting brackets towards the interior region of the frame 12. The lugs 92 prevent the lumbar support moving further rearwards when in the fully retracted position of FIG. 15 by mutual engagement with the respective side frame members 86 of the lumbar support.

[0079] The mounting plate 50′ extends on both sides of the cross-member 18 and includes a wide portion 94 above the cross-member 18 and a narrow portion 96 below, as can be best seen in FIG. 13. The narrow portion 96 comprises a tapered end of the plate 66′ and has a flat rearward facing surface 98 which accommodates a roller 100 coaxially mounted on pin 60′ between rollers 58′ at the distal end of the actuator. The roller 100 has a diameter slightly greater than that of the rollers 58′ and bears against the surface 98. The narrow portion 96 of the plate 50′ supports the distal end of the actuator 38 in operation when lateral forces are applied to the distal end of the actuator, in use, by reaction forces acting on the lumbar support 80.

[0080] In order to accommodate the roller 100, the cam plate 66′ is provided with a central cut out region 102 along part of its length. This allows the roller 100 free movement along the length of the cam plate 66′ as the actuator is extended and retracted.

[0081] Referring now to the drawings of FIGS. 17 to 21, in a third embodiment the seat back 10 comprises both the adjustable head rest 14 of FIGS. 1 to 7 and the adjustable lumbar support 80 of FIGS. 8 to 16. In the third embodiment, the seat back 10 comprises frame 12, adjustable headrest 14 and operating mechanism for adjusting the position of the headrest with respect to the frame, adjustable lumbar support 80 and operating mechanism for adjusting the position of the lumbar support with respect to the frame. In the drawings of FIGS. 17 to 19 the headrest and lumbar support are shown deployed, in the drawings of FIGS. 20 and 21 the same are shown in their closed/retracted positions.

[0082] In the embodiment of FIGS. 17 to 21, actuators 38 and 38′ for the adjustable headrest 14 and adjustable lumbar support 80 are arranged side by side on the cross-member 18 for independent control of the headrest adjustment and the lumbar support adjustment. As can be seen in the drawings, actuator 38′ for the lumbar support is arranged on the right hand side of actuator 38 for the headrest adjustment, when viewed in the front elevation view of FIG. 21. The remaining parts of the seat back are as previously described.

[0083] It is to be understood that in all embodiments the cam followers (rollers 58, 58′) engage the cam plate 66, 66′ when the actuator is extended from the fully retracted position. In preferred embodiments, the rollers 58, 58′ do not engage/contact the cam plate 66, 66′ when actuator 38, 38′ is fully retracted, the rollers and cam plate are disengaged in this configuration.

[0084] It will be understood that while the illustrated embodiments of FIGS. 1 to 21 concern a seat back suitable for a chair, preferably a recliner chair, the present invention also contemplates embodiments wherein the article of furniture is an adjustable bed, for example a bed having a recliner function in which the seat back or back rest is angularly adjustable relative to an adjacent section of the bed. In this respect it is to be understood that the term seat back used herein concerns not only seat backs for recliner chairs and the like but also backrests in beds etc, where adjustable lumbar and/or headrest support is commonly found.