Locking assembly for recliner

1 . A locking mechanism for a recliner assembly, the locking mechanism comprising:

a housing including:

a first plate defining a plurality of guide channels; and

a second plate received by the first plate, the second plate including a peripheral lip having an interior face that defines a plurality of teeth;

a cam disposed within the housing; and

a plurality of pawls disposed within the housing, each of the plurality of pawls positioned within a respective one of the plurality of guide channels, each of the plurality of pawls defining a plurality of pawl teeth, each of the plurality of pawls having a first side profile defining a first notch and a second side profile defining a second notch, the plurality of pawl teeth including first teeth and second teeth positioned between the first teeth, the first teeth having a different profile than the second teeth;

wherein the cam is configured to engage with the plurality of pawls to translate the plurality of pawls along the plurality of guide channels such that the plurality of pawl teeth engage with the plurality of teeth of the second plate; and

wherein the first notch and the second notch are configured to facilitate deformation of the first side profile and the second side profile, respectively, as at least one of the first side profile or the second side profile engages with a sidewall of a respective guide channel under certain loading conditions to prevent disengagement of the plurality of pawl teeth of the plurality of pawls from the plurality of teeth of the second plate.

2 . The locking mechanism of claim 1 , wherein:

the first side profile has a first outer face, a second outer face, and a first inner face positioned between the first outer face and the second outer face; and

the second side profile has a third outer face, a fourth outer face, and a second inner face positioned between the third outer face and the fourth outer face.

3 . The locking mechanism of claim 2 , wherein, under a normal loading condition, the first outer face and the second outer face are in contact with a first sidewall of the respective guide channel and the first inner face is not in contact with the first sidewall, and the third outer face and the fourth outer face are in contact with a second sidewall of the respective guide channel and the second inner face is not in contact with the second sidewall, the second sidewall opposing the first sidewall.

4 . The locking mechanism of claim 1 , wherein the first notch and the second notch reduce surface area of the first side profile and the second side profile in contact with the sidewalls and, thereby, are configured to reduce friction between the plurality of pawls and the plurality of guide channels as the plurality of pawls translate along the plurality of guide channels.

5 . The locking mechanism of claim 1 , wherein:

the cam is configured to engage with the plurality of pawls to reposition the plurality of pawls from (i) a first position where the plurality of pawls do not engage with the second plate to permit rotation between the first plate and the second plate and (ii) a second position where the plurality of pawls engage with the second plate to prevent rotation between the first plate and the second plate; and

the first notch and the second notch are configured to facilitate deformation of the first side profile and the second side profile under the certain loading conditions while the plurality of pawls are in the second position.

6 . The locking mechanism of claim 1 , wherein the plurality of pawls include four pawls.

7 . The locking mechanism of claim 1 , wherein each of the second teeth has one flat face and one curved face.

8 . The locking mechanism of claim 1 , wherein each of the first teeth have flat faces.

9 . The locking mechanism of claim 1 , wherein:

the certain loading conditions are first, higher loading conditions; and

under second, lower loading conditions, (a) faces of the first teeth do not contact corresponding teeth of the second plate and (b) one or more faces of the second teeth contact corresponding teeth of the second plate.

10 . A locking mechanism for a recliner assembly, the locking mechanism comprising:

a housing including:

a first portion defining a plurality of guide channels; and

a second portion received by the first portion, the second portion including a peripheral lip having an interior face that defines a plurality of teeth;

a cam disposed within the housing; and

a plurality of pawls disposed within the housing, each of the plurality of pawls positioned within a respective one of the plurality of guide channels, each of the plurality of pawls defining a plurality of pawl teeth, each of the plurality of pawls having (a) a first side profile with a first outer face, a second outer face, and a first inner face positioned between the first outer face and the second outer face such that a first notch is defined thereby and (b) a second side profile with a third outer face, a fourth outer face, and a second inner face positioned between the third outer face and the fourth outer face such that a second notch is defined thereby;

wherein the cam is configured to engage with the plurality of pawls to reposition the plurality of pawls from (i) a first position where the plurality of pawls do not engage with the second portion to permit rotation between the first portion and the second portion and (ii) a second position where the plurality of pawls engage with the second portion to prevent rotation between the first portion and the second portion; and

wherein, while the plurality of pawls are in the second position, the first notch and the second notch are configured to facilitate deformation of the first side profile and the second side profile, respectively, as at least one of the first side profile or the second side profile engages with a sidewall of a respective guide channel under certain loading conditions.

11 . The locking mechanism of claim 10 , wherein, under a normal loading condition, the first outer face and the second outer face are in contact with a first sidewall of the respective guide channel and the first inner face is not in contact with the first sidewall, and the third outer face and the fourth outer face are in contact with a second sidewall of the respective guide channel and the second inner face is not in contact with the second sidewall, the second sidewall opposing the first sidewall.

12 . The locking mechanism of claim 10 , wherein the plurality of pawls includes four pawls.

13 . A locking mechanism for a recliner assembly, the locking mechanism comprising:

a housing including:

a first portion defining a guide channel; and

a second portion received by the first portion, the second portion including a peripheral lip having an interior face that defines a plurality of teeth;

a cam disposed within the housing; and

a pawl disposed within the housing and positioned within the guide channel, the pawl defines a plurality of pawl teeth comprising first teeth and second teeth positioned between the first teeth, the pawl has a first side profile defining a first notch and a second side profile defining a second notch;

wherein the cam is configured to engage with the pawl to translate the pawl along the guide channel such that the plurality of pawl teeth engage with the plurality of teeth of the second portion; and

wherein the first notch and the second notch are configured to facilitate deformation of the first side profile and the second side profile, respectively, as at least one of the first side profile or the second side profile engages with a sidewall of the guide channel under first loading conditions to prevent disengagement of the plurality of pawl teeth of the pawl from the plurality of teeth of the second portion.

14 . The locking mechanism of claim 13 , wherein the first notch and the second notch of the pawl reduce surface area of the first side profile and the second side profile in contact with sidewalls of the guide channel and, thereby, are configured to reduce friction between the pawl and the guide channel as the pawl translates along the guide channel.

15 . The locking mechanism of claim 13 , wherein:

the first side profile has a first outer face, a second outer face, and a first inner face positioned between the first outer face and the second outer face; and

the second side profile has a third outer face, a fourth outer face, and a second inner face positioned between the third outer face and the fourth outer face.

16 . The locking mechanism of claim 15 , wherein, under second loading conditions lower than the first loading conditions, the first outer face and the second outer face are in contact with a first sidewall of the guide channel and the first inner face is not in contact with the first sidewall.

17 . The locking mechanism of claim 16 , wherein, under the second loading conditions, the third outer face and the fourth outer face are in contact with a second sidewall of the guide channel and the second inner face is not in contact with the second sidewall, the second sidewall opposing the first sidewall.

18 . The locking mechanism of claim 13 , wherein the cam is configured to engage with the pawl to reposition the pawl from (i) a first position where the pawl does not engage with the second portion to permit rotation between the first portion and the second portion and (ii) a second position where the pawl does engage with the second portion to prevent rotation between the first portion and the second portion.

19 . The locking mechanism of claim 18 , wherein the first notch and the second notch are configured to facilitate deformation of the first side profile and the second side profile under the first loading conditions while the pawl is in the second position.

20 . The locking mechanism of claim 13 , wherein:

each of the first teeth have flat faces; and

each of the second teeth has one flat face and one curved face.