Seat assembly pivot bracket

Abstract

The present disclosure provides a "seat assembly pivot bracket". A lifter mechanism for an edge of a seat cushion includes a bracket that is detachable from and rotatable about a crossbar. The bracket includes a forward lever and a rearward portion. The forward lever is coupled to a seat suspension. The rearward portion is coupled to a linkage. The linkage is coupled to a seat back. When the seat back pivots to a predetermined reclined position, the forward lever raises an edge of the seat suspension.

Description

Technical Field

[0001] The present invention generally relates to an apparatus and method for providing a motor vehicle seat assembly that is adapted to assume a first configuration during operation of the motor vehicle to provide conventional support and restraint and is adapted to assume a second configuration when the motor vehicle is not in operation to provide a relatively horizontal supine platform on which an occupant may lie, and more particularly to a hip lift mechanism that raises the trailing edge of a lower seat structure to the level of a seat back when the seat back is in a fully reclined position. Background Art

[0002] Motor vehicle seat assemblies provided in modern motor vehicles are primarily designed to provide a support platform that is designed to accommodate a motor vehicle occupant in a sitting or reclined position, thereby providing support for the back of the motor vehicle occupant through which the motor vehicle occupant may safely operate the motor vehicle or travel within the motor vehicle in a comfortable and enjoyable manner. Another function of the motor vehicle seat assembly is to assist in restraining the occupant in the event of a collision or rollover event. For example, in the case of a frontal collision event, the motor vehicle seat assembly is particularly adapted to restrain the occupant within a defined position range such that the active and passive restraint systems of the motor vehicle may operate appropriately.

[0003] With respect to the lower seat structure of the motor vehicle seat assembly, the lower seat structure typically slopes downward in a rearward direction toward the bite line of the motor vehicle seat assembly to provide an ergonomic seat platform. This configuration is also used to assist in positioning the H-point of the motor vehicle occupant of the motor vehicle seat assembly such that, in the event of a frontal collision, the forward momentum of the motor vehicle occupant creates a force against the lower seat assembly that tends to hold the motor vehicle occupant in a position where the active restraint system, including the seat belt assembly, and the passive restraint system, including one or more airbags, may be most effectively utilized.

[0004] However, modern motor vehicle seat assemblies generally do not address the needs of a motor vehicle occupant when the vehicle is parked and the motor vehicle occupant desires to rest or sleep. Due to the mechanisms widely used to provide seat back recline features, significant discomfort may be caused when the seat back is moved from a driving / use design position to a rest / sleep position. In particular, existing recline features tend to create a substantial vertical gap between the lower seat structure and the seat back when the seat back is in a fully reclined position. Similarly, when in a fully reclined position, the seat back often does not provide sufficient upper back support. Features that enable a motor vehicle occupant to be more comfortable and relaxed are needed. An apparatus that provides a relatively horizontal supine platform and sufficient upper back support is needed. Summary of the Invention

[0005] According to one aspect of the present invention, a lifter mechanism for an edge of a seat cushion includes a bracket that is detachable from a crossbar and rotatable about the crossbar. The bracket includes a forward lever and a rearward portion. The forward lever is coupled to a seat suspension. The rearward portion is coupled to a linkage. The linkage is coupled to a seat back. When the seat back pivots to a predetermined reclined position, the forward lever raises an edge of the seat suspension.

[0006] Embodiments of the first aspect of the present invention may include any one or combination of the following features:

[0007] · The forward lever includes a pin that is slidably coupled to a channel in the seat suspension;

[0008] · Each of the seat cushion and the seat back has an exposed surface, and wherein when the seat back is in a fully reclined position, the exposed surfaces of each of the seat cushion and the seat back substantially occupy the same horizontal plane;

[0009] · The linkage has a slot including an upper end and a lower end, and wherein the rearward portion of the bracket includes a pin received within the slot, wherein the lower end of the slot near the pin corresponds to an upright position of the seat back, and wherein an initial contact of the upper end of the slot with the pin corresponds to a predetermined reclined position between the upright position and the fully reclined position;

[0010] · Pivoting the seat back between the predetermined reclined position and the fully reclined position against the pin pushes the upper end of the slot to rotate the bracket and raises the forward lever and an edge of the seat cushion upward;

[0011] · The predetermined reclined position is about 55.5° relative to a vertical plane;

[0012] · The crossbar is an elongate rod, and the bracket includes a collar portion between the forward lever and the rearward portion, and the collar portion surrounds the elongate rod;

[0013] · The collar portion rotatably engages the elongate rod and includes opposing retaining features; wherein the elongate rod includes a pit, wherein a first distance from a first opposing edge of the pit to a second opposing edge of the pit is less than a diameter of the elongate rod; and wherein a second distance between the first opposing retaining feature and the second opposing retaining feature is greater than the first distance;

[0014] · The bracket slides onto the rod at the pit and moves to a position of the elongate rod having a constant diameter;

[0015] · The bracket includes a flange extending outwardly from the collar portion and laterally along the elongate rod;

[0016] · The flange includes a pair of flanges, wherein each of the one flanges is disposed on opposite sides of the bracket;

[0017] · When torque is applied to the bracket, the pair of flanges stabilize the bracket;

[0018] · A rib between the flange and the upper flange of the I-beam; and / or

[0019] · The bracket includes an I-beam structure.

[0020] According to another aspect of the present invention, a seat assembly for a motor vehicle includes a lower seat structure, the lower seat structure including: a seat frame; a seat suspension disposed adjacent to the seat frame; a pivot rod extending laterally between rearward portions of the seat frame; and a lower seat pivot mount disposed at the rear end of the seat frame; and a cushion assembly supported by the seat suspension. The seat back is pivotable between an upright position and a fully reclined position, and the seat back is operatively coupled to the lower seat structure. The seat back has a seat back pivot mount at its lower portion, which is operatively coupled to the lower seat pivot mount. The hip lifter mechanism includes a hip lifter pivot bracket, which is operatively coupled to the pivot rod and rotatably disposed relative to the pivot rod. The hip lifter mechanism further includes a slotted linkage coupled to the lower portion of the seat back frame. The hip lifter pivot bracket includes a forward lever, a rearward portion, and a collar portion having laterally opposed flanges. The forward lever of the hip lifter pivot bracket includes a forward lever and a rearward portion. When the seat back pivots to a predetermined reclined position between the upright position and the fully reclined position, the forward lever of the hip lifter pivot bracket raises the edge of the seat suspension upward. The rearward portion is coupled to the slotted linkage.

[0021] Embodiments of the second aspect of the present invention may include any one or combination of the following features:

[0022] · The suspension and the seat back can be arranged in a first configuration, a second configuration, and a third configuration

[0023] :

[0024] o The first configuration, in which the seat back is upright, the seat suspension is substantially horizontal, the protrusion attached to the forward lever is near the front end of the channel of the suspension, the pin attached to the rearward portion is near the lower portion of the slot in the slotted linkage, and the pivot bracket is in a substantially horizontal position;

[0025] o The second configuration, in which the seat back is in a predetermined reclined position, the suspension is substantially horizontal, the protrusion attached to the forward lever is near the front end of the channel, the pin attached to the rearward portion is initially in contact with the upper portion of the slot in the slotted linkage, and the pivot bracket is in a substantially horizontal position;

[0026] o A third configuration, in which the seat back is in a fully reclined position, the suspension is in a diagonal position, the protrusion attached to the forward joystick is near the rear end of the passage, the pin attached to the rearward portion contacts the upper part of the slot in the slotted linkage, and the pivot bracket is in a diagonal position.

[0027] · The pivot bracket rotates between the second configuration and the third configuration about the pivot rod;

[0028] · The predetermined reclined position is approximately 55.5° relative to the vertical plane; and / or

[0029] · The fully reclined position is approximately 85 degrees relative to the vertical plane.

[0030] According to another aspect of the present invention, the seat assembly forms a substantially horizontal plane for the exposed surfaces of each of the seat back cushion for the lower seat cushion and the seat back. The seat assembly includes a lifter mechanism for the rearward edge of the lower seat cushion, the lifter mechanism including a bracket pivotable about a crossbar fixedly mounted to the frame assembly for the seat. The bracket has an I-beam structure and includes a forward joystick and a rearward portion. A link is fixed at a first end to the seat back and the link is fixed at a second end to the rearward portion. When the seat back pivots to the predetermined reclined position, the rearward edge of the lower seat cushion is initially raised by the forward joystick. When the seat back pivots to the fully reclined position, the rearward edge of the lower seat cushion is raised to a substantially horizontal plane.

[0031] Upon studying the following specification, claims and drawings, those skilled in the art will understand and appreciate these and other aspects, objects and features of the present invention. Brief Description of the Drawings

[0032] In the drawings:

[0033] Figure 1 is a front perspective view of an automotive seat assembly installed in a motor vehicle according to the present disclosure, wherein the seat back of the front seat assembly is in an upright position;

[0034] Figure 2 is Figure 1 a front perspective view of the automotive seat assembly, wherein the seat back of the front row seat assembly is in a fully reclined position;

[0035] Figure 3A is Figure 1 a side view of the hip lifter mechanism of the automotive seat assembly, wherein the seat back is in an upright position;

[0036] Figure 3B is Figure 1 a side schematic view of the hip lifter mechanism of the automotive seat assembly, wherein the seat back is in an upright position;

[0037] Figure 4Yes Figure 1 Side view of the hip lifter mechanism of the vehicle seat assembly, where the seat back is in the fully reclined position;

[0038] Figure 5 Yes Figure 1 Side perspective view of the hip lifter mechanism of the vehicle seat assembly;

[0039] Figure 6 Yes Figure 1 Bottom perspective view of the hip lifter mechanism of the vehicle seat assembly, where the seat back is in the fully reclined position;

[0040] Figure 6A Yes Figure 1 Side schematic view of the hip lifter mechanism of the vehicle seat assembly, where the seat back is in the upright position;

[0041] Figure 6B Yes Figure 1 Side schematic view of the hip lifter mechanism of the vehicle seat assembly, where the seat back is in the first predetermined position;

[0042] Figure 6C Yes Figure 1 Side schematic view of the hip lifter mechanism of the vehicle seat assembly with the link removed, where the seat back is in the fully reclined position;

[0043] Figure 6D Yes Figure 1 Schematic side view of the hip lifter mechanism of the vehicle seat assembly with the link installed, where the seat back is in the fully reclined position;

[0044] Figure 7 Side perspective view of the hip lifter mechanism with the link installed, where the seat back is in the fully reclined position;

[0045] Figure 7A Side perspective view of the connection between the seat back frame and the lower seat;

[0046] Figure 8 Yes Figure 1 Partial front view of the hip lifter mechanism and the pad suspension system of the vehicle seat assembly;

[0047] Figure 9 Yes Figure 1 Side perspective view of the seat assembly of the vehicle seat assembly;

[0048] Figure 10 Top perspective view of the auxiliary suspension of the seat assembly;

[0049] Figure 11 Top view of the pad of the auxiliary suspension;

[0050] Figure 12 is a top view of the frame of the auxiliary suspension;

[0051] Figure 13 is a bottom perspective view of the auxiliary suspension;

[0052] Figure 14 is a side perspective view of the attachment clip of the auxiliary suspension;

[0053] Figure 15 is a bottom view of the auxiliary suspension;

[0054] Figure 16 is a top perspective view of the auxiliary suspension connected to the main suspension;

[0055] Figure 17 is a first side view of the pivot bracket;

[0056] Figure 18 is a perspective view of the retaining structure near the rear portion of the pivot bracket;

[0057] Figure 19 is a perspective view of the retaining feature of the forward lever near the pivot bracket;

[0058] Figure 20 is a first perspective view of the flange of the bracket;

[0059] Figure 21 is a second perspective view of the flange of the bracket;

[0060] Figure 22 is a top view of the bracket;

[0061] Figure 23 is a bottom view of the bracket;

[0062] Figure 24 is a front view of the bracket as viewed from the end of the forward lever;

[0063] Figure 25 is a rear view of the bracket as viewed from the end of the rear portion;

[0064] Figure 26 is a second side view of the bracket;

[0065] Figure 27 is along Figure 26 taken along XXVII-XXVII of Figure 26 a cross-sectional view of the bracket;

[0066] Figure 28 is a front view of the crossbar;

[0067] Figure 29 is a second front view of the crossbar with two pivot brackets; and

[0068] Figure 30 is a side view schematic diagram of a hip lifter mechanism, where the arrow shows the direction of movement when the hip lifter mechanism is activated. Detailed implementation

[0069] For the purpose of description, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", "inner", "outer" and their derivatives shall be related to Figure 1 the present invention in the orientation shown. However, it should be understood that unless explicitly stated to the contrary, the present invention may adopt various alternative orientations. It should also be understood that the specific devices and processes shown in the drawings and described in the following specification are only exemplary embodiments of the inventive concept defined in the appended claims. Therefore, unless the claims explicitly state otherwise, the specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0070] Refer to Figures 1 to 30 in, reference numeral 10 generally represents a vehicle seat assembly in a passenger compartment 8 of a motor vehicle 6. The motor vehicle seat assembly 10 includes a lower seat structure 12 pivotally coupled to an elevated seat back 14. As Figures 1 to 2 shown, the motor vehicle seat assembly 10 is typically configured for use in the front driver seat, front passenger seat, or rear seat of a motor vehicle 6 in various motor vehicles 6, and generally includes the aforementioned lower seat structure 12 and elevated seat back 14. A headrest 26 is also mounted on the top of the elevated seat back 14. The motor vehicle seat assembly 10 can be configured to be mounted on a support surface, such as a floor pan 28 of the vehicle 6. As is known, a seat track assembly 30 can be coupled to the lower seat structure 12 to facilitate the front-to-back positioning of the motor vehicle seat assembly 10. The motor vehicle seat assembly 10 is generally designed to comfort a motor vehicle occupant and to accommodate and protect the motor vehicle occupant during a collision event.

[0071] Refer to FIGS. 3A to Figure 4 , the hip lifter mechanism 120 for the edge 166 of the seat cushion (the cushion assembly 164 in the depicted aspect) includes a bracket 122 pivotable about a crossbar (the pivot bar 48 in the depicted aspect). The bracket 122 includes a forward lever 124 and a rearward portion 126. The forward lever 124 is coupled to a seat suspension (the auxiliary suspension 52 in the depicted aspect). The rearward portion 126 is coupled to a linkage 132. The linkage 132 is coupled to the seat back 14. When the seat back 14 pivots to a predetermined reclined position, the forward lever 124 raises the edge 166 of the cushion assembly 164.

[0072] Figure 7The seat assembly 10 in the fully reclined position is shown. The lower seat structure 12 includes a forward seat plate 34 and a pair of opposing lateral lower seat frame members 36, 38 having a front end 40 and a rear end 42, the front end 40 and the rear end 42 being attached to opposing side edges 44, 46 of the forward seat plate 34 at the front ends 40 of the pair of opposing lateral lower seat frame members 36, 38. A pivot rod 48 extends laterally between the rear ends 42 of the pair of opposing lateral lower seat frame members 36, 38 and is fixedly attached to the rear ends 42 of the pair of opposing lateral lower seat frame members 36, 38. Preferably, the forward seat plate 34 and the pair of opposing lateral lower seat frame members 36, 38 are made of relatively low weight and high strength metal components (such as high strength steel or aluminum). A lower seat pivot mount 50 is installed at the rear ends 42 of the pair of opposing lateral lower seat frame members 36, 38.

[0073] Reference Figures 7 to 9 , an auxiliary suspension 52 is attached to the main suspension 54 and is adjustably supported between the pair of opposing lateral lower seat frame members 36, 38. The auxiliary suspension 52 includes a frame 56 and a cushion 74.

[0074] The seat back 14 is pivotable between an upright position ( Figure 1 , FIGS. 3A, 3B, Figure 6A , Figure 30 ) and a fully reclined position ( Figure 2 , Figure 4 , Figure 6 , Figure 6D , Figure 7 ) and is operatively coupled to the lower seat structure 12. The seat back 14 includes a frame 90 having an upper transverse member 92, a lower transverse member 94, and a pair of opposing lateral seat back frame members 96, 98 extending vertically between the upper transverse member 92 and the lower transverse member 94. Each of the pair of opposing lateral seat back frame members 96, 98 has a seat back pivot mount 100 at its lower portion, and the seat back pivot mount 100 is operatively coupled to the lower seat pivot mount 50. Preferably, the seat back pivot mount 100 on each of the pair of opposing lateral seat back frame members 96, 98 includes a circular recess 112, and the lower seat pivot mount 50 installed on each of the pair of opposing lateral lower seat frame members 36, 38 includes a circular protrusion 114 received within the circular recess 112.

[0075] Reference Figure 5, the motor vehicle seat assembly 10 further includes a hip lifter mechanism 120, which includes a pair of hip lifter pivot brackets 122 (also referred to as pivot brackets 122 or brackets 122), and the pair of hip lifter pivot brackets 122 are operatively coupled to the pivot rod 48 and are pivotally disposed relative to the pivot rod 48. Each of the hip lifter pivot brackets 122 is preferably formed in a collar shape, which fits over the pivot rod 48 and is supported by the pivot rod 48. Each of the pair of hip lifter pivot brackets 122 is preferably disposed adjacent to one of the pair of opposite side lower seat frame members 36, 38. As Figures 6 to 6D and Figure 7 shown, each of the hip lifter pivot brackets 122 includes a forward lever 124 and a rearward portion 126. The forward lever 124 of each of the pair of hip lifter pivot brackets 122 is also preferably laterally disposed between the pair of opposite side lower seat frame members 36, 38 and is located below one of the pair of laterally opposite side seat back frame members 96, 98 in the upright position. So configured, the forward lever 124 of the hip lifter pivot bracket 122 includes a protrusion 128 that slidably engages the channel 130 of the auxiliary suspension 52 and raises the auxiliary suspension 52 when further rotated toward the fully reclined position.

[0076] Referring again to Figures 6 to 6D , a pair of slotted linkages 132 are operatively coupled to the (preferably) lower portions 134 of the opposite side seat back frame members 96, 98. Alternatively, the slotted linkages 132 can be attached to the lower transverse cross member 94 of the frame 90 of the seat back 14. In various aspects, the slotted linkages 132 can be welded to the lower portions 134 of the opposite side seat back frame members 96, 98 or welded to the lower transverse cross member 94 of the frame 90 of the seat back 14. The slotted linkages 132 are pivotally attached or fixed to the arm 143 at the first end 140 and pivotally attached or fixed to the rearward portion 126 of the hip lifter pivot bracket 122 at the second end 142. The pivotal attachment of the first end 140 of the slotted linkage 132 to the arm 143 of the seat back 14 is preferably achieved through a connector 144 that is fixed within the openings 146, 148 in each of the first end 140 of the slotted linkage 132 and the arm 143, thereby allowing relative pivotal movement. As Figures 6 to 6DAs shown, the slot linkage 132 is provided with a slot 150 that is adjacent to the second end 142 of the slot linkage 132, and this second end 142 is operatively coupled to the rearward portion 126 of the hip lifter pivot bracket 122. The slot 150 of the slot linkage 132 has an upper end 152 and a lower end 154. The rearward portion 126 of the hip lifter pivot bracket 122 is coupled to a pin 156 that is received within the slot 150. In various aspects, the slot linkage 132 can be a link or linkage of various shapes, sizes, and designs.

[0077] In operation, each forward joystick 124 includes a protrusion 128 that moves within the channel 130 of the auxiliary suspension 52. That is, when the seat back 14 is in the upright position, the lower end 154 of the slot 150 is adjacent to the pin 156 disposed within the rearward portion 126, as Figure 6A shown. Thus, when the lower end 154 of the slot 150 is adjacent to the pin 156, the position of the seat back 14 corresponds to the upright position of the seat back 14. Similarly, when the seat back 14 is reclined, the upper end 152 of the slot 150 initially contacts the pin 156 disposed within the rearward portion 126, where the position of the seat back 14 corresponds to a predetermined reclined position between the upright position and the fully reclined position, as Figure 6B shown. Preferably, the predetermined reclined position of the seat back 14 is approximately 55.5° relative to the vertical plane. Further rotation of the seat back 14 toward the fully reclined position causes the rearward portion 126 of the hip lifter pivot bracket 122 to shift further downward, which in turn causes the hip lifter pivot bracket 122 to rotate and raise the forward joystick 124, which then pushes the protrusion 128 to move rearward within the channel 130 of the auxiliary suspension 52. When the seat back pivots beyond Figure 6A the upright position in Figure 6D and Figure 6B the predetermined reclined position between the fully reclined position in

[0078] As best shown in FIGS. 3A, 3B, and Figure 4 each of the lower seat structure 12 and the seat back 14 has an exposed surface 160, 162, respectively. Preferably, the exposed surface 160 includes a locally flexible / elastic decorative material relative to the cushion assembly 164, which can move to keep the decorative material and foam of the cushion assembly 164 in a stretched state to maintain a flat surface and eliminate wrinkles. In particular, by moving the seat back 14 to the fully reclined position, the rear edge 166 of the cushion assembly 164 of the lower seat structure 12 is raised such that the auxiliary suspension 52 raises the exposed surface 160 of the cushion assembly 164 to substantially occupy the same horizontal plane as the exposed surface 162 of the seat back 14 when the seat back 14 is in the fully reclined position. By comparison Figure 6CThe relative exposed surfaces 160, 162 in [reference] can best understand this benefit, where the slotted linkage 132 has been removed and the hip lifter mechanism 120 is thus disabled, where Figure 6D The relatively exposed surfaces 160, 162 are shown in [reference], where the slotted linkage 132 is installed and the exposed surfaces 160, 162 occupy substantially the same plane.

[0079] Referring Figure 9 , preferably, the hip lifter mechanism 120 will assist the suspension 52 and the cushion assembly 164 to raise a distance H between 45 mm and 70 mm between the upright position and the fully reclined position of the seat back 14, to eliminate the pressure on the waist and raise the coccyx and hips of the occupant, as Figure 9 shown. The result is a substantially flat and continuous surface from the exposed surfaces 160, 162 of the cushion assembly 164 and the seat back 14 respectively. Referring Figure 4 , preferably, the fully reclined position of the seat back 14 is about 85° from the vertical direction. The fully reclined position of the seat assembly 10 extends from the front edge 168 of the lower seat structure 12 to the upper part 170 of the seat back 14. The upper part 170 of the seat back 14 is adjustable relative to the back of the seat back 14.

[0080] In addition, the slotted linkage 132 for the hip lifter mechanism 120 provides a passive system that automatically raises the height of the lower seat structure cushion assembly 164 once the seat back 14 reaches the desired sleep start angle (here preferably 55.5° from the vertical direction), and achieves the maximum lift of the cushion assembly 164 once the seat back 14 reaches the maximum sleep angle (here preferably 85° from the vertical direction). An additional benefit of the hip lifter mechanism 120 disclosed herein is that the forward joystick 124 is coupled to the auxiliary suspension 52 and is disposed between the opposing side lower seat frame members 36, 38 so as not to affect the seat assembly H-point or comfort when the seat back 14 of the seat assembly 10 is not in the fully reclined position or sleep mode. Further, by relatively simple changes to the system geometry, such as the shape and length of the slot 150, the maximum lift height of the rear edge 166 of the cushion assembly 164 of the lower seat structure 12 can be easily modified and adjusted for a specific application.

[0081] In addition, the hip lifter mechanism 120 represents a relatively simple mechanical system that can be manually actuated and does not require a motor, but a power-actuated vehicle seat assembly can also advantageously employ the disclosed hip lifter mechanism 120. Additionally, existing seat backs 14, recline latch controls 172, and associated mechanisms can be readily used to hold the seat back 14 in a desired reclined position between the upright position and the fully reclined position while providing a lift function for the rear edge 166 of the lower seat structure cushion assembly 164 beyond a predetermined reclined position. Finally, the provided hip lifter mechanism 120 is readily adaptable as a retrofit device for an existing motor vehicle seat assembly 10.

[0082] Thus, in terms of a motor vehicle occupant desiring to rest in a supine position when the motor vehicle 6 is not in operation, the foregoing disclosure only provides a platform upon which the motor vehicle occupant can rest. According to the foregoing disclosure, a more comfortable sleep seat surface can now be provided by raising the height of the rear edge 166 of the cushion assembly 164 of the lower seat structure 12 to make the overall surface more level and the transition from the cushion assembly 164 to the seat back 14 less pronounced.

[0083] Reference Figures 10 to 11 , the auxiliary suspension 52 includes a frame 56 and a cushion 74. The cushion 74 includes a generally rectangular central portion 180. The generally rectangular central portion 180 has attachment features 182, 184 at opposite ends of the generally rectangular central portion 180. Two additional attachment features 186, 188 are at the cross member 68 of the frame 56. The attachment feature 182 includes a hole 190 for receiving a nub 76. Similarly, the attachment feature 184 includes a hole 192 for receiving a nub 76. The attachment feature 186 includes a hole 212 for receiving a nub 210. The attachment feature 188 includes a hole 212 for receiving a nub 210. In various aspects, the cushion 74 is made of a load-bearing, flexible, creep-resistant, and durable material. One such suitable load-bearing material is DYMETROL material available from ACMEMills. The inwardly extending members 70, 72 of the frame 56 include clips 82. The clamp 86 covers the clip 82.

[0084] Figure 12 is a top view of the frame 56. The frame 56 includes an internal C-shaped member 58 and an external C-shaped member 60. During the manufacture of the frame 56, an internal C-shaped wire 59 and an external C-shaped wire 61 are used. The internal C-shaped wire 59 and the external C-shaped wire 61 have a diameter of approximately 0.8 mm, which is overmolded with a glass-filled nylon portion 62. The attachment clips 82 and the nubs 76 are designed in the mold. In various aspects, the frame 56 is removed from the mold as Figure 12 depicted. Reference Figures 11 to 12, in all aspects, the small piece 76 is hook-shaped for respectively receiving the holes 190, 192 of the attachment features 182 and 184 of the cushion 74. The frame 56 includes a pair of laterally opposite frame members 64, 66 and a cross member 68 extending between the pair of laterally opposite frame members 64, 66. The inwardly extending members 70, 72 extend from the laterally opposite frame members 64, 66.

[0085] Reference Figure 13 , the auxiliary suspension 52 can be seen from the bottom. The flanges 200 project from the bottoms of the laterally opposite frame members 64 and 66. In all aspects, the flange 200 is part of a curved U-shaped member 208. In the depicted aspect, four molded small pieces 210 are located on the lower side of the glass-filled nylon portion 62 of the outer C-shaped member 60 of the frame 56. The attachment features 186 and 188 of the cushion 74 include holes 212 for receiving the small pieces 210. The small pieces 210 are generally hook-shaped. The frame 56 includes an inner C-shaped wire 59, an outer C-shaped wire 61, and a glass-filled nylon portion 62. In all aspects, the frame 56 can be described as having a rectangular shape.

[0086] Reference Figure 14 and Figure 16 , the clip 82 projects from the inwardly extending member 72. In all aspects of the present disclosure, the clip 82 can be another type of fastener for fixing the suspension (the auxiliary suspension 52 in the depicted aspect) to the lower seat structure 12. The circular opening 83 in the clip 82 receives the circular member of the main suspension 54. In the depicted aspect, the circular member wire 84. The clip 82 is pivotally coupled around the wire 84.

[0087] Reference Figure 15 , a bottom perspective view of the auxiliary suspension 52 is shown. The cushion 74 is attached to the frame 56. The flanges 200 extend from the laterally opposite frame members 64, 66 of the frame 56. Each flange 200 includes a channel 130. When the auxiliary suspension 52 is placed in the seat assembly 10 in the vehicle 6 in the forward direction, the channel 130 has a front portion 202 and a rearward portion 204.

[0088] Reference Figure 16 , it is shown that the auxiliary suspension 52 is attached to the main suspension 54 using the clip 82. The clamp 86 fixes the clip 82 to the wire 84 of the main suspension 54. A pair of channels 130 are located on a pair of flanges 200 extending from the bottom of the frame 56 of the auxiliary suspension 52. Each channel 130 includes a front portion 202 and a rearward portion 204. The opening 206 is close to the channel 130. In all aspects, the auxiliary suspension 52 and the main suspension 54 can be molded as an integral part in one tool. The clamp 86 fixes the auxiliary suspension 52 to the main suspension 54 (the auxiliary suspension 52 in the depicted aspect).

[0089] Reference Figures 17 to 30 shows the pivot bracket 122. Reference Figure 17 The pivot bracket 122 includes a forward joystick 124 and a rearward portion 126. Reference Figure 6 and Figure 17 The forward joystick 124 includes a protrusion 128 for engaging with the channel 130 of the auxiliary suspension 52. The rearward portion 126 includes a hole 157 for receiving a pin 156 that attaches the rearward portion 126 to a slot 150 in the slotted linkage 132. In various aspects of the present disclosure, the forward joystick 124 can be a cantilever beam. The bracket 122 includes an I-beam structure 220 that strengthens the bracket 122. The I-beam structure 220 includes an upper flange 222 and a lower flange 224. The pivot bracket 122 includes a collar portion 230. The collar portion 230 is defined by a retaining member 232 on the side of the forward joystick 124 of the bracket 122 and a retaining member 240 on the side of the rearward portion 126 of the bracket 122. In the depicted aspect, the retaining members 232 and 240 are generally opposite each other.

[0090] Reference Figure 18 The retaining member 240 includes a first protrusion 242 and a second protrusion 244 positioned near the rearward portion 126 of the bracket 122.

[0091] Reference Figure 19 The retaining member 232 includes a first protrusion 234 and a second protrusion 236 positioned near the forward joystick 124 of the bracket 122.

[0092] Reference Figures 17 to 19 There is a distance D1 between the retaining member 232 and the retaining member 240. The distance D1 refers to the distance between the opposing first protrusion 242 of the retaining member 240 and the second protrusion 236 of the retaining member 232 and between the opposing second protrusion 244 of the retaining member 240 and the first protrusion 234 of the retaining member 232.

[0093] Reference Figures 20 to 21 The bracket 122 is shown in a first perspective view and a second perspective view. The bracket 122 includes a forward joystick 124 and a rearward portion 126. The bracket 122 is manufactured with an I-beam structure 220. The I-beam structure 220 includes an upper flange 222 and a lower flange 224. The lower flange 224 includes outward flanges 274, 276 which are part of the collar portion 230 of the bracket 122. When the pivot bracket 122 is coupled to the pivot rod 48, the flanges 274, 276 stabilize the pivot bracket 122. The protrusion 128 is located on the forward joystick 124. Reference Figure 6 、 Figure 20 and Figure 21, the protrusion 128 is connected to the channel 130 of the auxiliary suspension 52. The hole 157 for receiving the pin 156 to connect the bracket 122 to the slot 150 is located on the rearward portion 126 of the bracket 122.

[0094] Reference Figures 22 to 23 , a top view and a bottom view of the bracket 122 are shown respectively. The top view of the bracket 122 includes the forward lever 124 and the rearward portion 126. The flanges 274, 276 protrude from the bracket 122. The ribs 282 provide additional strength to the flanges 274, 276. Regarding Figure 23 , the collar portion 230 of the bracket 122 is shown inside the flanges 274, 276. Reference Figure 22 And Figure 23 , the protrusion 128 and the forward lever 124 are also shown.

[0095] Reference Figures 24 to 25 , a front view and a rear view of the bracket 122 are shown respectively. Figure 24 The front view of includes the forward lever 124 with the protrusion 128. Reference Figure 25 , the rear view of the bracket 122 includes the rearward portion 126.

[0096] Reference Figure 26 , a second side view of the bracket 122 is shown. In Figure 27 , a cross-section of the bracket 122 taken along line XXVII-XXVII is shown. In all aspects, the pivot bracket 122 is made of glass-filled acetal and has a steel rod 290 passing through the center.

[0097] Reference Figure 28 , the pivot rod 48 is shown. The pivot rod 48 has a pit 250. The pivot rod 48 also has a first end 252 and a second end 253. The first end 252 of the pivot rod 48 has annular protrusions 254, 255, 256. The second end 253 of the pivot rod 48 has annular protrusions 262, 263. The pit 250 has a first part 266 and a second part 268.

[0098] Reference Figure 29, a pair of pivot brackets 122 are on the pivot rod 48. The first pivot bracket 270 is located between the annular protrusion 256 and the pit 250. The first pivot bracket 270 has a first flange 274 and a second flange 276. The first flange 274 abuts against the annular protrusion 256. The second pivot bracket 272 has a first flange 278 and a second flange 280. The second flange 280 abuts against the annular protrusion 262. To place the first pivot bracket 270 and the second pivot bracket 272 on the pivot rod 48 during the assembly of the seat assembly 10, the first pivot bracket 270 slides on the pit 250 and moves adjacent to the annular protrusion 256. Similarly, the second pivot bracket 272 slides on the pit 250 and moves adjacent to the annular protrusion 262. In the depicted aspect, the pivot rod 48 is an elongated rod. In operation, the first pivot bracket 270 and the second pivot bracket 272 are operatively coupled to a position on the pivot rod 48 having a constant diameter. Refer to Figure 28 and Figure 29 , in various aspects of the present disclosure, the pivot rod 48 may have a first portion that spans a distance D2 across the pit 250 and a second portion having a diameter D3. The diameter D3 is greater than the distance D2. The pivot brackets 122 are mounted on the elongated rod (the pivot rod 48 in the depicted aspect) at the first portion having the first distance D2 and moved to the second portion having a diameter D3 for operation.

[0099] Refer to Figure 30 , the hip lifter mechanism 120 is shown in a schematic view in an initial state, where the seat back 14 is upright. The arrow 294 depicts the direction of movement when the hip lifter mechanism is activated from the upright position of the seat back towards the fully reclined position.

[0100] The seat assembly pivot brackets are also disclosed in co-pending application 83892388, assigned to the same assignee Ford Global Technologies, LLC, entitled "SEATING ASSEMBLY WITH SUSPENSION", the entire content of which is incorporated herein by reference in its entirety.

[0101] In various aspects of the present disclosure, a seat suspension (exemplarily shown as an auxiliary suspension 52 in the depicted aspect) may be coupled to various types of lower seat structures, which may or may not have a suspension below (exemplarily shown as a main suspension 54 in the depicted aspect).

[0102] Those of ordinary skill in the art will understand that the construction and other components of the present invention are not limited to any particular material. Unless otherwise specified herein, other exemplary embodiments of the present disclosure disclosed herein may be formed of a variety of materials.

[0103] For the purposes of this disclosure, the term "coupled" (in all its forms, coupled, coupled to, coupled with, etc.) generally means that two components (electrical or mechanical) are connected to each other either directly or indirectly. Such a connection can be fixed in nature or movable in nature. Such a connection can be achieved using two components (electrical or mechanical), and any additional intermediate members can be integrally formed with each other as a single unit or formed integrally with the two components. Unless otherwise stated, such a connection can be permanent in nature or can be removable or releasable in nature.

[0104] For the purposes of this disclosure, the term "operatively connected" generally means that one component functions with respect to another component, even if there are other components between the first and second components, and the term "operable" defines the functional relationship between the components.

[0105] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments are merely illustrative. While only a few embodiments of the innovation have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily understand that many modifications are possible (e.g., variations in the size, dimensions, structure, shape and proportions of the various elements, values of parameters, mounting arrangements, materials used, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed can be constructed of multiple parts, or elements shown as multiple parts can be integrally formed, the operation of the interfaces can be reversed or otherwise varied, the length or width of the structure and / or members or the connectors or other elements of the system can be changed, the nature or amount of adjustment positions provided between the elements can be changed. It should be noted that the elements and / or components of the system can be constructed of any of a variety of materials, which provide adequate strength or durability in any of a variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the innovation. Other substitutions, modifications, changes, and omissions can be made in the design, operating positions, and arrangements of the desired and other exemplary embodiments without departing from the spirit of the innovation.

[0106] It should be understood that any of the described processes or steps within the described processes can be combined with other disclosed processes or steps to form structures within the scope of this disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be construed as limiting.

[0107] It should be understood that variations and modifications can be made to the foregoing structures without departing from the concepts of the invention, and it should also be understood that such concepts are intended to be covered by the appended claims unless these claims state otherwise in their language.

[0108] According to the present invention, there is provided a lifter mechanism for the edge of a seat cushion, having a bracket that is detachable from a crossbar and rotatable about the crossbar, wherein the bracket includes a forward lever connected to a seat suspension and a rearward portion connected to a linkage, and the linkage is connected to a seat back, wherein when the seat back is pivoted to a predetermined reclined position, the forward lever raises the edge of the seat suspension.

[0109] According to one embodiment, the forward lever includes a pin that is slidably connected to a channel in the seat suspension.

[0110] According to one embodiment, each of the seat cushion and the seat back has an exposed surface, and wherein when the seat back is in the fully reclined position, the exposed surfaces of each of the seat cushion and the seat back substantially occupy the same horizontal plane.

[0111] According to one embodiment, the linkage has a slot including an upper end and a lower end, and wherein the rearward portion of the bracket includes a pin received within the slot, wherein the lower end of the slot near the pin corresponds to the upright position of the seat back, and wherein the initial contact of the upper end of the slot with the pin corresponds to a predetermined reclined position between the upright position and the fully reclined position.

[0112] According to one embodiment, pivoting the seat back between the predetermined reclined position and the fully reclined position against the pin pushes the upper end of the slot to rotate the bracket and raise the forward lever and the edge of the seat cushion upward.

[0113] According to one embodiment, the predetermined reclined position is about 55.5° relative to the vertical plane.

[0114] According to one embodiment, the crossbar is an elongated rod, and the bracket includes a collar portion between the forward lever and the rearward portion, and the collar portion surrounds the elongated rod.

[0115] According to one embodiment, the collar portion rotatably engages the elongated rod and includes opposing retaining features; wherein the elongated rod includes a pit, wherein a first distance from a first opposing edge of the pit to a second opposing edge of the pit is less than the diameter of the elongated rod; and wherein a second distance between the first opposing retaining feature and the second opposing retaining feature is greater than the first distance.

[0116] According to one embodiment, the bracket slides onto the rod at the pit and moves to a position on the elongated rod having a constant diameter.

[0117] According to one embodiment, the bracket includes a flange extending outwardly from the collar portion and laterally along the elongated rod.

[0118] According to one embodiment, the flange includes a pair of flanges, wherein each of the pair of flanges is disposed on opposite sides of the bracket.

[0119] According to one embodiment, when torque is applied to the bracket, the pair of flanges stabilize the bracket.

[0120] According to one embodiment, the invention further features ribs between the flange and the upper flange of the I-beam.

[0121] According to one embodiment, the bracket includes an I-beam configuration.

[0122] According to the present invention, there is provided a seat assembly for a motor vehicle, having: a lower seat structure, which further includes: a seat frame; a seat suspension disposed adjacent to the seat frame; a pivot rod extending laterally between rearward portions of the seat frame; a lower seat pivot mount disposed at the rear end of the seat frame; and a cushion assembly supported by the seat suspension; and a seat back pivotable between an upright position and a fully reclined position and operatively coupled to the lower seat structure, wherein the seat back has a seat back pivot mount at its lower portion, and the seat back pivot mount is operatively coupled to the lower seat pivot mount; and a hip lifter mechanism, which further includes a hip lifter pivot bracket and a slotted linkage, the hip lifter pivot bracket being operatively coupled to the pivot rod and rotatably disposed relative to the pivot rod, the slotted linkage being coupled to a lower portion of the seat back frame, wherein the hip lifter pivot bracket includes a forward actuating lever, a rearward portion, and a collar portion having laterally opposed flanges, wherein when the seat back pivots to a predetermined reclined position between the upright position and the fully reclined position, the forward actuating lever of the hip lifter pivot bracket raises the edge of the seat suspension, and wherein the rearward portion is coupled to the slotted linkage.

[0123] According to one embodiment, the suspension and the seat back can be arranged in a first configuration, a second configuration, and a third configuration as follows: a first configuration, wherein the seat back is upright, the seat suspension is substantially horizontal, a protrusion attached to the forward actuating lever is near the front end of the channel of the seat suspension, a pin attached to the rearward portion is near the lower portion of the slot in the slotted linkage, and the pivot bracket is in a substantially horizontal position; a second configuration, wherein the seat back is in a predetermined reclined position, the suspension is substantially horizontal, the protrusion attached to the forward actuating lever is near the front end of the channel, the pin attached to the rearward portion is initially in contact with the upper portion of the slot in the slotted linkage, and the pivot bracket is in a substantially horizontal position; and a third configuration, wherein the seat back is in the fully reclined position, the suspension is in a diagonal position, the protrusion attached to the forward actuating lever is near the rear end of the channel, the pin attached to the rearward portion is in contact with the upper portion of the slot in the slotted linkage, and the pivot bracket is in a diagonal position.

[0124] According to one embodiment, the pivot bracket rotates about the pivot rod between the second configuration and the third configuration.

[0125] According to one embodiment, the predetermined reclined position is about 55.5° relative to the vertical plane.

[0126] According to one embodiment, the fully reclined position is about 85 degrees relative to the vertical plane.

[0127] According to the present invention, there is provided a seat assembly that forms a substantially horizontal plane for the exposed surfaces of each of a lower seat cushion and a seat back cushion of a seat backrest, the seat assembly having a lifter mechanism for a rearward edge of the lower seat cushion, the lifter mechanism further including a bracket pivotable about a crossbar fixedly mounted to a frame assembly of the seat, the bracket having an I-beam structure and including a forward lever and a rearward portion; and a link fixed at a first end to the seat back and at a second end to the rearward portion; wherein when the seat back is pivoted to the predetermined reclined position, the rearward edge of the lower seat cushion is initially raised by the forward lever, and when the seat back is pivoted to the fully reclined position, the rearward edge of the lower seat cushion is raised to the substantially horizontal plane.

Claims

1. A lifter mechanism for an edge of a seat cushion, comprising: A main suspension and an auxiliary suspension; A bracket that is detachable from a crossbar and rotatable about the crossbar, wherein the bracket includes a forward lever coupled to the auxiliary suspension and a rearward portion coupled to a linkage, and the linkage is coupled to a seat back, wherein when the seat back pivots to a predetermined reclined position, the forward lever raises an edge of the auxiliary suspension, wherein the forward lever includes a pin that is slidably coupled to a channel in the auxiliary suspension.

2. The lifter mechanism according to claim 1, wherein each of the seat cushion and the seat back has an exposed surface, and wherein when the seat back is in a fully reclined position, the exposed surfaces of each of the seat cushion and the seat back substantially occupy the same horizontal plane.

3. The lifter mechanism according to claim 2, wherein the linkage has a slot including an upper end and a lower end, and wherein the rearward portion of the bracket includes a pin received within the slot, wherein the lower end of the slot adjacent the pin corresponds to an upright position of the seat back, and wherein an initial contact of the upper end of the slot with the pin corresponds to the predetermined reclined position between the upright position and the fully reclined position.

4. The lifter mechanism according to claim 3, wherein pivoting the seat back between the predetermined reclined position and the fully reclined position against the pin pushes the upper end of the slot to rotate the bracket and raise the forward lever and the edge of the seat cushion upward.

5. The lifter mechanism according to claim 1, wherein the predetermined reclined position is about 55.5° relative to a vertical plane.

6. The lifter mechanism according to claim 1, wherein the crossbar is an elongate rod, and the bracket includes a collar portion between the forward lever and the rearward portion, and the collar portion surrounds the elongate rod.

7. The lifter mechanism according to claim 6, wherein the collar portion rotatably engages the elongate rod and includes opposing retention features; wherein the elongate rod includes a pit, wherein a first distance from a first opposing edge of the pit to a second opposing edge of the pit is less than a diameter of the elongate rod; and wherein a second distance between a first opposing retention feature and a second opposing retention feature is greater than the first distance.

8. The lifter mechanism according to claim 7, wherein the bracket slides onto the elongate rod at the pit and moves to a position on the elongate rod having a constant diameter.

9. The lifter mechanism according to claim 6, wherein the bracket includes a flange extending outwardly from the collar portion and laterally along the elongate rod.

10. The lifter mechanism according to claim 9, wherein the flange includes a pair of flanges, wherein each of the pair of flanges is disposed on an opposite side of the bracket.

11. The lifter mechanism according to claim 10, wherein when torque is applied to the bracket, the pair of flanges stabilize the bracket.

12. The lifter mechanism according to claim 9, wherein, The bracket includes an I-beam structure that includes an upper flange and a lower flange, and the lifter mechanism further includes ribs between the flange and the upper flange of the I-beam.

13. The lifter mechanism according to claim 1, wherein the bracket includes an I-beam configuration.

14. A vehicle that includes the lifter mechanism according to any one of claims 1-13.

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