Collapsible recliner mechanism

Abstract

A recliner mechanism of a recliner to facilitate shipment and final assembly of the recliner mechanism includes a first side linkage, second side linkage, and at least one support member coupling the first and second side linkages. The first and second side linkages each may include a respective seat deck link configured to couple to a seat deck of the recliner and a respective back rest link configured to couple to a back rest of the recliner. The support member extends from a first end pivotally coupled to the first side linkage to a second end pivotally coupled to the second side linkage. The first side linkage is movable relative to the second side linkage from a collapsed configuration to an expanded configuration.

What is claimed is: 
     
         1 . A recliner mechanism of a recliner comprising:
 a first side linkage comprising a first seat deck link configured to couple to a seat deck of the recliner and a first back rest link configured to couple to a back rest of the recliner;   a second side linkage comprising a second seat deck link configured to couple to the seat deck of the recliner and a second back rest link configured to couple to the back rest of the recliner; and   at least one support member having a first end coupled to the first side linkage and a second end coupled to the second side linkage, wherein the first side linkage is movable relative to the second side linkage from a collapsed configuration to an expanded configuration.   
     
     
         2 . The recliner mechanism of  claim 1 , wherein the at least one support member comprises at least one of a cross tube, a torque tube, and a drive tube. 
     
     
         3 . The recliner mechanism of  claim 1 , wherein the first end of the at least one support member is coupled to the first side linkage at a first pivot point and the second end of the at least one support member is coupled to the second side linkage at a second pivot point, and wherein the first side linkage and the second side linkage are movable about the first pivot point and the second pivot point from the collapsed configuration to the expanded configuration. 
     
     
         4 . The recliner mechanism of  claim 1 , wherein the first end of the at least one support member and the second end of the at least one support member is configured to mechanically lock to the respective first and second side linkage in the expanded configuration. 
     
     
         5 . The recliner mechanism of  claim 1 , wherein the first end of the at least one support member and the second end of the at least one support member is configured to receive a respective first and second fastener to mechanically lock to the respective first and second side linkage in the expanded configuration. 
     
     
         6 . The recliner mechanism of  claim 1 , wherein the at least one support member comprises a hinged tube comprising:
 a first section coupled to the first side linkage at the first pivot point; and   a second section coupled the second side linkage at the second pivot point; and   a hinge section comprising a third pivot point, wherein the first section is movably coupled to the second section at the third pivot point,   wherein the first section is substantially parallel to the second section in the expanded configuration.   
     
     
         7 . The recliner mechanism of  claim 6 , wherein the hinge section further comprises a detent is configured to resist movement of the first section and the second section from the expended configuration toward the collapsed configuration. 
     
     
         8 . The recliner mechanism of  claim 6 , wherein the hinge section further comprises a stop tab extending from at least a portion of the first section and configured to contact at least a portion of the second section when in the expanded configuration. 
     
     
         9 . The recliner mechanism of  claim 6 , wherein the first section and the second section define respective apertures configured to receive therethrough respective fasteners to secure the first section and the second section to the respective first and second side linkages when in the expanded configuration. 
     
     
         10 . The recliner mechanism of  claim 1 , wherein the at least one support member comprises a first tube section and a second tube section concentric to the first tube section and coupled to the first tube section in a sliding engagement between the collapsed configuration and the expanded configuration. 
     
     
         11 . The recliner mechanism of  claim 10 , wherein the at least one support member further comprises a third tube section concentric to the second tube section and coupled to the second tube section in a sliding engagement between the collapsed configuration and the expanded configuration. 
     
     
         12 . The recliner mechanism of  claim 10 , wherein at least one of the first tube section or the second tube section defines an aperture configured to receive therethrough a fastener to mechanically coupled the first tube section to the second tube section in the expanded configuration. 
     
     
         13 . The recliner mechanism of  claim 12 , wherein the fastener comprises at least one of a bolt or a spring lock. 
     
     
         14 . A recliner mechanism of a recliner comprising:
 a first side linkage comprising a first seat deck link configured to couple to a seat deck of the recliner and a back rest link extending in a first plane and configured to couple to a back rest of the recliner;   a second side linkage comprising a second seat deck link configured to couple to the seat deck of the recliner and a second back rest link extending in a second plane substantially parallel to the first plane and configured to couple to the back rest of the recliner;   at least one hinged tube comprising:
 a first section having a first end coupled to the first side linkage and a second end; and 
 a second section having a third end coupled to the second side linkage and a fourth end pivotally coupled to the second end of the first section, 
   wherein the recliner mechanism is configured to move between a collapsed configuration and an expanded configuration.   
     
     
         15 . The recliner mechanism of  claim 14 , wherein, when in the expanded configuration, the first section extends substantially perpendicular to the first plane, the second section extends substantially perpendicular to the second plane, and the first section and the second are aligned in a substantially parallel arrangement. 
     
     
         16 . The recliner mechanism of  claim 14 , wherein, when in the collapsed configuration, the first section extends from the first plane at a first angle less than 90-degrees, the second section extends from the second plane at a second angle less than 90-degrees, and the first section is positioned relative to the second section at a third angle less than 180-degrees. 
     
     
         17 . A method of manufacturing a recliner mechanism, comprising:
 pivotally coupling a first end of a support member to a first side linkage, wherein the first side linkage comprises a first plurality of links substantially extending parallel to a first plane;   pivotally coupling a second end of the support member to a second side linkage, wherein the second side linkage comprises a second plurality of links substantially extending parallel to a second plane, wherein the first plane is substantially parallel to the second plane; and   moving the recliner mechanism from an expanded configuration toward a collapsed configuration, wherein a distance D 1  between the first plane and the second plane in the expanded configuration is less than a distance D 2  between the first plane and the second plane in the collapsed configuration.   
     
     
         18 . The method of  claim 17 , wherein the method further comprises pivotally coupling a first section of the support member to a second section of the support member. 
     
     
         19 . The method of  claim 18 , wherein the method further comprises:
 forming on the first section and the second section respective corresponding detents, wherein the detents are configured to resist movement of the first section and the second section from the expended configuration toward the collapsed configuration; and   forming on the first section a stop tab, wherein the stop tab is configured to contact at least a portion of the second section when in the expanded configuration.   
     
     
         20 . A method of assembling a recliner mechanism comprising a first side linkage having a first plurality of links substantially extending parallel to a first plane, a second side linkage having a second plurality of links substantially extending parallel to a second plane substantially parallel to the first plane, and a support member pivotally coupled at a first end to the first side linkage and pivotally coupled at a send end to the second side linkage, comprising:
 positioning the recliner mechanism on a work surface, wherein the first plane and the second plane are substantially perpendicular to the work surface;   moving the recliner mechanism from a collapsed configuration toward an expanded configuration, wherein a distance D 1  between the first plane and the second plane in the expanded configuration is less than a distance D 2  between the first plane and the second plane in the collapsed configuration; and   securing the recliner mechanism in the expanded configuration.   
     
     
         21 . The method of  claim 20 , wherein securing the recliner mechanism in the expanded configuration comprises installing at least one fastener to mechanically lock the first end of the support member to the first side linkage, the second end of the support member to the second side linkage, or both. 
     
     
         22 . The method of  claim 20 , wherein the support member comprises a first section and a second section pivotally coupled to the first section, wherein securing the recliner mechanism in the expanded configuration comprises installing at least one fastener to mechanically lock the first section to the second section in the expanded configuration.