Seat assembly with suspension

Abstract

The present disclosure provides a "seat assembly with a suspension". A lifting mechanism for an edge of a seat cushion includes a bracket pivotable about a crossbar. The bracket includes a front rod and a rear portion. The front rod is coupled to a channel within a flange of a seat suspension. The rear portion is coupled to a linkage mechanism. The linkage mechanism is coupled to a seat back. When the seat back is pivoted to a predetermined reclined position, the front rod 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 to provide conventional support and restraint during operation of the motor vehicle and is adapted to assume a second configuration to provide a relatively horizontal reclined platform on which an occupant may lie when the motor vehicle is not in operation, and more particularly, to a hip lift mechanism that raises the rear edge of the lower seat structure to the seat back level when in the 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 can safely operate the motor vehicle or travel within the motor vehicle in a manner that is both comfortable and enjoyable. Another function of the motor vehicle seat assembly is to assist in restraining the occupant in the event of a crash or rollover event. For example, in the case of a frontal crash 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 can operate properly.

[0003] In the case of the lower seat structure of a motor vehicle seat assembly, the lower seat structure generally 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 help locate the H-point of the motor vehicle occupant of the motor vehicle seat assembly, whereby in the case of a frontal crash event, 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 in which the active restraint system, including the seat belt assembly, and the passive restraint system, including one or more airbags, can be most effectively employed.

[0004] However, modern motor vehicle seat assemblies generally do not address the needs of the 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 can be caused when the seat back is moved from the driving / use design position to the rest / sleep position. In particular, existing recline features tend to create a rather large vertical gap between the lower seat structure and the seat back, where the seat back is in the fully reclined position. Similarly, when in the fully reclined position, the seat back generally does not provide sufficient upper back support. Features are needed that make the motor vehicle occupant more comfortable and relaxed. An apparatus is needed that provides a relatively horizontal reclined platform and sufficient upper back support. Summary of the Invention

[0005] According to one aspect of the present invention, a lifting mechanism for the edge of a seat cushion includes a bracket pivotable about a crossbar. The bracket includes a front rod and a rear portion. The front rod is coupled to a channel within a flange of a seat suspension. The rear portion is coupled to a linkage mechanism. The linkage mechanism is coupled to a seat back. When the seat back pivots to a predetermined reclined position, the front rod raises the edge of the seat cushion assembly.

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

[0007] · 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;

[0008] · The linkage mechanism has a slot that includes an upper end and a lower end, and wherein the rear portion of the bracket is coupled to 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 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;

[0009] · Pivoting the seat back between the predetermined reclined position and the fully reclined position forces the upper end of the slot against the pin to rotate the bracket and raise the front rod and the edge of the seat cushion assembly;

[0010] · The front rod is coupled to a protrusion, and wherein the protrusion is slidably received within the channel of the seat suspension;

[0011] · The seat suspension is in a substantially horizontal position in the predetermined reclined position, and wherein pivoting the seat back from the predetermined reclined position to the fully reclined position forces the protrusion to slide from the front portion of the channel to the rear portion of the channel to rotate the front edge of the seat suspension about a pivotable coupler to raise the rear portion of the seat suspension; and / or

[0012] · The predetermined reclined position is approximately 55.5° relative to the vertical plane.

[0013] According to another aspect of the present invention, a seat assembly for a motor vehicle includes a lower seat structure that includes: a seat frame; a seat suspension disposed adjacent to the seat frame; a pivot bar that extends laterally between rear portions of the seat frame; and a lower seat pivot support disposed at a rear end of the seat frame; and a seat cushion assembly supported by the seat suspension. The seat backrest is pivotable between an upright position and a fully reclined position, and the fully reclined position is operatively coupled to the lower seat structure. The seat backrest has a seat backrest pivot support at its lower portion, which is operatively coupled to the lower seat pivot support. The hip lift mechanism includes a hip lift pivot bracket that is operatively coupled to the pivot bar and is rotatably disposed relative to the pivot bar. The hip lift mechanism further includes a slotted link mechanism coupled to a lower portion of the seat backrest frame. The hip lift pivot bracket includes a front bar and a rear portion. The front bar of the hip lift pivot bracket is operatively coupled to an edge of the seat suspension via a passage within a flange to raise the edge of the seat suspension when the seat backrest pivots to a predetermined reclined position between the upright position and the fully reclined position. The rear portion is coupled to the slotted link mechanism.

[0014] Embodiments of the second aspect of the present invention may include one or a combination of the following features:

[0015] · The seat suspension includes a pair of laterally opposed suspension frame members and a suspension cross member extending between the pair of laterally opposed suspension frame members, and the pair of laterally opposed suspension frame members include bumps for securing a cushion to the pair of laterally opposed suspension members;

[0016] · An inwardly extending member projects from at least one of the pair of laterally opposed suspension frame members, and wherein the inwardly extending member is coupled to the lower seat structure;

[0017] · The inwardly extending member includes a circular opening pivotally coupled to a circular member of the lower seat structure;

[0018] · The seat suspension includes a suspension frame, a fastener coupled to the suspension frame, and a cushion coupled to the suspension frame, wherein the fastener couples the suspension frame to the lower seat structure;

[0019] · The suspension frame has a rectangular shape, and wherein the suspension frame includes bumps for receiving attachments of the cushion;

[0020] · The suspension frame includes a wire overmolded with fiberglass-filled nylon;

[0021] · The bumps are hook-shaped and made of fiberglass-filled nylon;

[0022] · Each of the lower seat structure and the seat back has an exposed surface, and when the seat back is in the fully reclined position, the exposed surfaces of each of the lower seat structure and the seat back substantially occupy the same horizontal plane;

[0023] · The linkage mechanism includes a slot and the slot includes an upper end and a lower end, and the rear portion of the hip lift pivot 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 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;

[0024] · A pair of hip lift mechanisms, wherein each of the pair of hip lift mechanisms is disposed near one of the pair of opposite side lower seat frame members; and / or

[0025] · The hip lift mechanism raises the seat suspension and the seat cushion assembly 45 mm to 70 mm between the upright position and the fully reclined position of the seat back.

[0026] According to another aspect of the present invention, a seat assembly forms a substantially horizontal plane for the exposed surfaces of each of a lower seat cushion and a seat back cushion for a seat back. The seat assembly includes a lift mechanism for a rear edge of the lower seat cushion, the lift mechanism including a bracket pivotable about a crossbar fixedly mounted to a frame assembly for the seat. The bracket includes a front rod operatively connected to the lower seat cushion and a rear portion. A link is pinned at a first end to the seat back and the link is pinned at a second end to the rear portion. When the seat back is pivoted to a predetermined reclined position, the front rod first raises the rear edge of the lower seat cushion. When the seat back is pivoted to the fully reclined position, the rear edge of the lower seat cushion is raised to a substantially horizontal plane.

[0027] Those skilled in the art will appreciate and understand these and other aspects, objects, and features of the present invention by studying the following specification, claims, and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In the drawings:

[0029] 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 row seat assembly is in the upright position;

[0030] 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 the fully reclined position;

[0031] Figure 3A is Figure 1Side view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the upright position;

[0032] Figure 3B is Figure 1 Schematic side view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the upright position;

[0033] Figure 4 is Figure 1 Side view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the fully reclined position;

[0034] Figure 5 is Figure 1 Perspective side view of the hip lifting mechanism of an automotive seat assembly;

[0035] Figure 6 is Figure 1 Bottom perspective view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the fully reclined position;

[0036] Figure 6A is Figure 1 Schematic side view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the upright position;

[0037] Figure 6B is Figure 1 Schematic side view of the hip lifting mechanism of an automotive seat assembly, where the seat back is in the first predetermined position;

[0038] Figure 6C is from Figure 1 Schematic side view of the hip lifting mechanism with the link removed from an automotive seat assembly, where the seat back is in the fully reclined position;

[0039] Figure 6D is Figure 1 Schematic side view of the hip lifting mechanism with the link installed in an automotive seat assembly, where the seat back is in the fully reclined position;

[0040] Figure 7 Perspective side view of the hip lifting mechanism with the link installed, where the seat back is in the fully reclined position;

[0041] Figure 7A Perspective side view of the connection between the seat back frame and the lower seat;

[0042] Figure 8 is Figure 1 Partial front view of the hip lifting mechanism and the seat cushion suspension system of an automotive seat assembly;

[0043] Figure 9 isFigure 1 Perspective side view of the seat assembly of the motor vehicle seat assembly;

[0044] Figure 10 Is a top perspective view of the auxiliary suspension of the seat assembly;

[0045] Figure 11 Is a top plan view of the cushion of the auxiliary suspension;

[0046] Figure 12 Is a top plan view of the frame of the auxiliary suspension;

[0047] Figure 13 Is a bottom perspective view of the auxiliary suspension;

[0048] Figure 14 Is a perspective side view of the attachment clip of the auxiliary suspension;

[0049] Figure 15 Is a bottom plan view of the auxiliary suspension;

[0050] Figure 16 Is a top perspective view of the auxiliary suspension connected to the main suspension;

[0051] Figure 17 Is a first side view of the pivot bracket;

[0052] Figure 18 Is a perspective view of the retaining feature near the rear of the pivot bracket;

[0053] Figure 19 Is a perspective view of the retaining feature near the front rod of the pivot bracket;

[0054] Figure 20 Is a first perspective view of the flange of the bracket;

[0055] Figure 21 Is a second perspective view of the flange of the bracket;

[0056] Figure 22 Is a top plan view of the bracket;

[0057] Figure 23 Is a bottom plan view of the bracket;

[0058] Figure 24 Is a front view of the bracket taken from the end of the front rod;

[0059] Figure 25 Is a rear view of the bracket taken from the rear end;

[0060] Figure 26 Is a second side view of the bracket;

[0061] Figure 27 Is Figure 26 The bracket ofFigure 26 Cross-sectional view taken along XXVII-XXVII;

[0062] Figure 28 is a front view of the crossbar;

[0063] Figure 29 is a second front view of the crossbar with two pivot brackets; and

[0064] Figure 30 is a side schematic view of the hip-lift mechanism, which shows the direction of movement when the hip-lift structure is activated by an arrow. Detailed Description

[0065] For the purposes described herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", "inner", "outer" and their derivatives shall relate to the present invention as defined in Figure 1 . 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 merely exemplary embodiments of the inventive concept defined in the appended claims. Accordingly, unless the claims otherwise expressly state, the specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0066] Refer to Figures 1 to 30 , reference numeral 10 generally denotes a vehicle seat assembly for a vehicle seat 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 generally configured for use as a front driver seat, a front passenger seat or a rear seat in various motor vehicles 6, and generally includes the aforementioned lower seat structure 12 and seat back 14. A headrest 26 is also mounted to the top of the elevated seat back 14. The motor vehicle seat assembly 10 may be configured to be mounted on a support surface, such as a floor pan 28 of the vehicle 6. As is well known, a seat rail assembly 30 may be coupled to the lower seat structure 12 to facilitate the front-to-rear positioning of the motor vehicle seat assembly 10. The motor vehicle seat assembly 10 is generally designed to provide comfort to a motor vehicle occupant and to accommodate and protect the motor vehicle occupant during a collision event.

[0067] Refer to Figures 3A to 4, the hip lift mechanism 120 for the edge 166 of the seat cushion (in the depicted aspect, the seat cushion assembly 164) includes a bracket 122 pivotable about a crossbar (in the depicted aspect, the pivot bar 48). The bracket 122 includes a front bar 124 and a rear portion 126. The front bar 124 is coupled to a channel 130 within a flange 200 of a seat suspension (in the depicted aspect, the auxiliary suspension 52). The rear 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 front bar 124 raises the edge 166 of the seat cushion assembly 164.

[0068] Figure 7 The seat assembly 10 is shown in a fully reclined position. The lower seat structure 12 includes a front seat plate 34 and a pair of opposing side lower seat frame members 36, 38 having a front end 40 and a rear end 42, the pair of opposing side lower seat frame members being attached to opposing lateral edges 44, 46 of the front seat plate 34 at the front end 40 of the pair of opposing side lower seat frame members 36, 38. The pivot bar 48 extends laterally between the rear ends 42 of the pair of opposing side lower seat frame members 36, 38 and is fixedly attached thereto. Preferably, the front seat plate 34 and the pair of opposing side lower seat frame members 36, 38 are made of relatively lightweight and high-strength metal components (such as high-strength steel or aluminum). The lower seat pivot support 50 is mounted at the rear ends 42 of the pair of opposing side lower seat frame members 36, 38.

[0069] Reference Figures 7 to 9 , the auxiliary suspension 52 is attached to the main suspension 54 and is adjustably supported between the pair of opposing side lower seat frame members 36, 38. The auxiliary suspension 52 includes a frame 56 and a cushion 74.

[0070] The seat back 14 is pivotable between an upright position ( Figure 1 , Figure 3A , Figure 3B , Figure 6A , Figure 30 ) and a fully reclined position ( Figure 2 , Figure 4 , Figure 6 , Figure 6D , Figure 7) pivot therebetween and is operatively coupled to the lower seat structure 12. The seat back 14 includes a frame 90 having an upper transverse beam 92, a lower transverse beam 94, and a pair of opposing lateral seat back frame members 96, 98 extending vertically between the upper transverse beam 92 and the lower transverse beam 94. Each of the pair of opposing lateral seat back frame members 96, 98 has a seat back pivot support 100 at its lower portion, which is operatively coupled to the lower seat pivot support 50. Preferably, the seat back pivot support 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 support 50 mounted on each of the pair of opposing lower seat frame members 36, 38 includes a circular protrusion 114 received within the circular recess 112.

[0071] Reference Figure 5 , the motor vehicle seat assembly 10 further includes a hip lift mechanism 120, which includes a pair of hip lift pivot brackets 122 (also referred to as pivot brackets 122 or brackets 122), the pair of hip lift pivot brackets being operatively coupled to the pivot rod 48 and pivotally disposed relative to the pivot rod. Each of the hip lift pivot brackets 122 is preferably formed in a collar shape that fits over and is supported by the pivot rod 48. Each of the pair of hip lift pivot brackets 122 is preferably disposed near one of the pair of opposing lower seat frame members 36, 38. As Figures 6 to 6D and Figure 7 shown, each of the hip lift pivot brackets 122 includes a front rod 124 and a rear portion 126. The front rod 124 of each of the pair of hip lift pivot brackets 122 is also preferably laterally disposed between the pair of opposing lower seat frame members 36, 38 and is in an upright position below one of the pair of opposing lateral seat back frame members 96, 98. With such an arrangement, the front rod 124 of the hip lift pivot bracket 122 includes a protrusion 128 that slidably engages the channel 130 of the auxiliary suspension 52 and lifts the auxiliary suspension 52 when further rotated toward the fully reclined position.

[0072] Referring again to Figures 6 to 6D, a pair of slotted link mechanisms 132 are operatively coupled to the lower portions 134 of the opposing lateral seat back frame members 96, 98. Optionally, the slotted link mechanisms 132 may be attached to the lower transverse beam 94 of the frame 90 of the seat back 14. In various aspects, the slotted link mechanisms 132 may be welded to the lower portions 134 of the opposing lateral seat back frame members 96, 98 or welded to the lower transverse beam 94 of the frame 90 of the seat back 14. The slotted link mechanism 132 is pivotally attached or pinned to the arm 143 at the first end 140 and pivotally attached or pinned to the rear portion 126 of the hip lift pivot bracket 122 at the second end 142. The pivotal attachment of the first end 140 of the slotted link mechanism 132 to the arm 143 of the seat back 14 is preferably achieved by a connector 144 that is fixed within openings 146, 148 in the first end 140 of the slotted link mechanism 132 and the arm 143, respectively, thereby allowing relative pivotal movement. As Figures 6 to 6D shown, the slotted link mechanism 132 is provided with a slot 150 that is adjacent to the second end 142 of the slotted link mechanism 132 and that is operatively coupled to the rear portion 126 of the hip lift pivot bracket 122. The slot 150 of the slotted link mechanism 132 has an upper end 152 and a lower end 154. The rear portion 126 of the hip lift pivot bracket 122 is coupled to a pin 156 that is received within the slot 150. In various aspects, the slotted link mechanism 132 may be a link or linkage of various shapes, sizes, and designs.

[0073] In operation, each of the front rods 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 rear 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 rear 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 further displaces the rear portion 126 of the hip lift pivot bracket 122 downward, which in turn causes the hip lift pivot bracket 122 to rotate and raise the front rods 124, and then forces the protrusions 128 to move rearward within the channels 130 of the auxiliary suspension 52. When the seat back pivots beyond Figure 6B the predetermined reclined position in Figure 6A the upright position andFigure 6D between the fully reclined positions.

[0074] As Figure 3A , Figure 3B and Figure 4 best shown in Figure 6C , 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 / stretch trim material relative to the seat cushion assembly 164, which can move to keep the trim material and foam of the seat cushion assembly 164 in a stretched state to maintain a flat surface and eliminate wrinkles. Specifically, by moving the seat back 14 to the fully reclined position, the rear edge 166 of the seat cushion assembly 164 of the lower seat structure 12 is raised, so that the auxiliary suspension 52 raises the exposed surface 160 of the seat 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 comparing the Figure 6C relative exposed surfaces 160, 162 (the slotted link mechanism 132 has been removed and the hip lift mechanism 120 is thus disabled) with the Figure 6D relative exposed surfaces 160, 162 shown in Figure 6D (the slotted link mechanism 132 is installed and the exposed surfaces 160, 162 occupy substantially the same plane), the benefit can be best understood.

[0075] Referring to Figure 9 , preferably, the hip lift mechanism 120 raises the auxiliary suspension 52 and the seat cushion assembly 164 by 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 lift the coccyx and hips of the occupant, as Figure 9 Figure 9 shown in Figure 9 . As a result, the exposed surfaces 160, 162 of the seat cushion assembly 164 and the seat back 14 are substantially flat and continuous surfaces, respectively. Referring to Figure 4 , preferably, the fully reclined position of the seat back 14 is at an angle of about 85° with respect to 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 portion 170 of the seat back 14. The upper portion 170 of the seat back 14 is adjustable relative to the rear portion of the seat back 14.

[0076] In addition, the slotted link mechanism 132 for the hip lift mechanism 120 provides a passive system that automatically raises the height of the seat cushion assembly 164 of the lower seat structure once the seat back 14 reaches the desired starting angle of the recline (preferably 55.5° from the vertical direction here), and once the seat back 14 reaches the maximum recline angle (preferably 85° from the vertical direction here), the passive system will achieve the maximum lift of the seat cushion assembly 164. An additional benefit of the hip lift mechanism 120 disclosed herein is that the front rod 124 is coupled to the auxiliary suspension 52 and is disposed between the lower seat frame members 36, 38 on the opposite side 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 the recline mode. In addition, 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 seat cushion assembly 164 of the lower seat structure 12 can be easily modified and fine-tuned according to the specific application.

[0077] In addition, the hip lift mechanism 120 represents a relatively simple mechanical system that can be manually actuated and does not require a motor, although a power-actuated vehicle seat assembly can also advantageously employ the disclosed hip lift mechanism 120. Additionally, the existing seat back 14, recline latch control 172, and associated mechanisms can be easily 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 seat cushion assembly 164 of the lower seat structure to extend beyond the predetermined reclined position. Finally, the provided hip lift mechanism 120 can be easily adapted for use in a retrofit device for an existing motor vehicle seat assembly 10.

[0078] Thus, to the extent that a motor vehicle occupant wishes to lie in a supine position and rest when the motor vehicle 6 is not in operation, the foregoing disclosure only provides such a platform on which the motor vehicle occupant can rest. According to the foregoing disclosure, a more comfortable sleeping seat surface can now be provided by raising the height of the rear edge 166 of the seat cushion assembly 164 of the lower seat structure 12 so that the entire surface is more level and the transition from the seat cushion assembly 164 to the seat back 14 is less noticeable.

[0079] 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 crossbeam 68 of the frame 56. The attachment feature 182 includes a hole 190 for receiving a bump 76. Similarly, the attachment feature 184 includes a hole 192 for receiving a bump 76. The attachment feature 186 includes a hole 212 for receiving a bump 210. The attachment feature 188 includes a hole 212 for receiving a bump 210. In various aspects, the cushion 74 is made of a load-bearing, flexible, creep-resistant, and robust material. One such suitable load-bearing material is DYMETROL material available from ACME Mills. The inwardly extending members 70, 72 of the frame 56 include clips 82. The clamp 86 covers the clip 82.

[0080] Figure 12 is a top plan 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, and these wires are overmolded with a glass fiber-filled nylon portion 62. The attachment clips 82 and the bumps 76 are designed in the mold. In various aspects, as Figure 12 depicted, the frame 56 is removed from the mold. Refer to Figures 11 to 12 , in various aspects, the bumps 76 are hook-shaped for receiving the holes 190, 192 of the attachment features 182 and 184 of the cushion 74, respectively. The frame 56 includes a pair of laterally opposed frame members 64, 66 and a crossbeam 68 extending between the pair of laterally opposed frame members 64, 66. The inwardly extending members 70, 72 extend from the laterally opposed frame members 64, 66.

[0081] Refer to Figure 13 , the auxiliary suspension 52 can be seen from the bottom. Flanges 200 project from the bottoms of the laterally opposed frame members 64 and 66. In various aspects, the flanges 200 are part of a curved U-shaped member 208. In the depicted aspect, four molded bumps 210 are located on the lower side of the glass fiber-filled nylon portion 62 of the external C-shaped member 60 of the frame 56. The attachment features 186 and 188 of the cushion 74 include holes 212 for receiving the bumps 210. The bumps 210 are generally hook-shaped. The frame 56 includes an internal C-shaped wire 59, an external C-shaped wire 61, and a glass fiber-filled nylon portion 62. In various aspects, the frame 56 can be described as having a rectangular shape.

[0082] Refer to Figure 14 and Figure 16, clip 82 projects from the inwardly extending member 72. In various aspects of the present disclosure, clip 82 can be another type of fastener for securing a suspension (in the depicted aspect, auxiliary suspension 52) to the lower seat structure 12. The circular opening 83 in clip 82 receives the circular member of the main suspension 54. In the depicted aspect, circular member line 84. Clip 82 is pivotally coupled about line 84.

[0083] Reference Figure 15 , a bottom perspective view of the auxiliary suspension 52 is shown. Pad 74 is attached to the frame 56. 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, channel 130 has a front portion 202 and a rear portion 204.

[0084] Reference Figure 16 , the auxiliary suspension 52 is shown as being attached to the main suspension 54 using clip 82. Fixture 86 secures clip 82 to the line 84 of the main suspension 54. A pair of channels 130 are located on a pair of flanges 200 that extend from the bottom of the frame 56 of the auxiliary suspension 52. Each channel 130 includes a front portion 202 and a rear portion 204. Opening 206 is adjacent to channel 130. In various aspects, the auxiliary suspension 52 and the main suspension 54 can be molded as integral parts in one tool. Fixture 86 secures the auxiliary suspension 52 to the main suspension 54 (in the depicted aspect, auxiliary suspension 52).

[0085] Reference Figures 17 to 30 , the pivot bracket 122 is shown. Reference Figure 17 , the pivot bracket 122 includes a front rod 124 and a rear portion 126. Reference Figure 6 And Figure 17 , the front rod 124 includes a protrusion 128 for engaging with the channel 130 of the auxiliary suspension 52. The rear portion 126 includes a hole 157 for receiving a pin 156 that attaches the rear portion 126 to the slot 150 in the slotted link mechanism 132. In various aspects of the present disclosure, the front rod 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 front rod 124 of the bracket 122 and a retaining member 240 on the side of the rear portion 126 of the bracket 122. In the depicted aspect, the retaining members 232 and 240 are generally opposite to each other.

[0086] Reference Figure 18 , the retaining member 240 includes a first protrusion 242 and a second protrusion 244 located near the rear portion 126 of the bracket 122.

[0087] Reference Figure 19 , the retaining member 232 includes a first protrusion 234 and a second protrusion 236 located near the front rod 124 of the bracket 122.

[0088] Reference Figures 17 to 19 , the distance D1 is between the retaining member 232 and the retaining member 240. The distance D1 refers to the distances 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.

[0089] Reference Figures 20 to 21 , the bracket 122 is shown in a first perspective view and a second perspective view respectively. The bracket 122 includes a front rod 124 and a rear 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. The protrusion 128 is on the front rod 124. Reference Figure 6 , Figure 20 and Figure 21 , the protrusion 128 is coupled to the channel 130 of the auxiliary suspension 52. The hole 157 for receiving the pin 156 to couple the bracket 122 to the slot 150 is located on the rear portion 126 of the bracket 122.

[0090] Reference Figures 22 to 23 , a top view of the bracket 122 and a bottom view of the bracket 122 are shown respectively. The top view of the bracket 122 includes the front rod 124 and the rear 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 within the flanges 274, 276. Reference Figure 22 and Figure 23 , the protrusion 128 and the front rod 124 are also shown.

[0091] Reference Figures 24 to 25 , a front view of the bracket 122 and a rear view of the bracket 122 are shown respectively. Figure 24 The front view of includes the front rod 124 with the protrusion 128. Reference Figure 25 , the rear view of the bracket 122 includes the rear portion 126.

[0092] Reference Figure 26 , a second side view of the bracket 122 is shown. Figure 27Shows a cross-section of the pivot bracket 122 taken at line XXVII-XXVII. In various aspects, the pivot bracket 122 is made of fiberglass-filled acetal and has a steel rod 290 passing through the center.

[0093] Reference Figure 28 , shows the pivot rod 48. 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.

[0094] 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 the annular protrusion 256. The second pivot bracket 272 has a first flange 278 and a second flange 280. The second flange 280 abuts 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 over the pit 250 and moves near the annular protrusion 256. Similarly, the second pivot bracket 272 slides over the pit 250 and moves near 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. Reference Figure 28 and Figure 29 , in various aspects of the present disclosure, the pivot rod 48 may have a first part passing through the pit 250 at a distance D2 and a second part having a diameter D3. The diameter D3 is greater than the distance D2. The pivot bracket 122 is mounted on the elongated rod (in the depicted aspect, the pivot rod 48) at the first part at a first distance D2 and moves to the second part having a diameter D3 for operation.

[0095] Reference Figure 30 , the hip lift 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 lift mechanism is activated from the upright position of the seat back towards the fully reclined position.

[0096] A seat assembly with a suspension is also disclosed in co-pending co-assigned Ford Global Technologies, LLC application 83892334 entitled SEATING ASSEMBLY PIVOT BRACKET, the entire content of which is incorporated herein by reference in its entirety.

[0097] In various aspects of the present disclosure, a seat suspension (exemplarily shown as the auxiliary suspension 52 in the depicted aspect) can be coupled to various types of lower seat structures, which may or may not have an underlying suspension (exemplarily shown as the main suspension 54 in the depicted aspect).

[0098] Those of ordinary skill in the art will understand that the structures and other components of the present disclosure are not limited to any specific material. Unless otherwise described herein, other exemplary embodiments of the present disclosure disclosed herein can be formed from a variety of materials.

[0099] For the purposes of the present disclosure, the term "couple" (in all its forms, couple, coupling, coupled, etc.) generally means that two components (electrical or mechanical) are directly or indirectly connected to each other. Such a connection can be fixed in nature or movable in nature. Such a connection can be achieved by the two components (electrically or mechanically), and any additional intermediate members can be integrally formed with each other as a single unit or integrally formed with the two components. Unless otherwise specified, such a connection can be permanent in nature or can be removable or releasable.

[0100] For the purposes of the present disclosure, the term "operatively connected" generally means that one component acts in relation to another component, even if there are other components between the first component and the second component, and the term "operable" defines the functional relationship between the components.

[0101] It is also important to note that the structures and arrangements of the elements of the present disclosure as shown in the exemplary embodiments are merely illustrative. Although only a few embodiments of the present invention are described in detail in this disclosure, those skilled in the art will readily understand that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter, unless otherwise described (e.g., variations in the size, dimensions, structure, shape and proportions, parameter values, mounting arrangements, material uses, colors, orientations, etc. of various elements). For example, elements shown as integrally formed may be composed of multiple parts, or elements shown as multiple parts may be integrally formed, the interface operations may be reversed or otherwise varied, the lengths or widths of the structures and / or members or connectors or other elements of the system may be varied, and the nature or number of adjustment positions for changing between elements may be set. It should be noted that the elements and / or assemblies of the system may be composed of any of a variety of materials, which provide sufficient 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 this innovation. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangements of the desired and other exemplary embodiments without departing from the spirit of the present invention.

[0102] It should be understood that any of the described processes or steps in the processes may 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.

[0103] It should be understood that changes and modifications may be made to the foregoing structures without departing from the concepts of this disclosure, and it should also be understood that these concepts are intended to be covered by these claims unless the appended claims state otherwise in their language.

[0104] According to the present invention, there is provided a lifting mechanism for an edge of a seat cushion, the lifting mechanism having a bracket pivotable about a crossbar, wherein the bracket includes a front rod and a rear portion, the front rod being coupled to a channel within a flange of a seat suspension, the rear portion being coupled to a linkage mechanism, wherein the linkage mechanism is coupled to a seat back, and wherein when the seat back is pivoted to a predetermined reclined position, the front rod raises the edge of the seat suspension.

[0105] According to an embodiment, 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.

[0106] According to an embodiment, the linkage mechanism has a slot that includes an upper end and a lower end, and wherein a rear portion of the bracket is coupled to 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.

[0107] According to an embodiment, pivoting the seat back between the predetermined reclined position and the fully reclined position forces the upper end of the slot against the pin to rotate the bracket and raises the front rod and an edge of the seat cushion upward.

[0108] According to an embodiment, the front rod is coupled to a convex portion, and wherein the convex portion is slidably received within a channel of the seat suspension.

[0109] According to an embodiment, the seat suspension is in a substantially horizontal position in the predetermined reclined position, and wherein pivoting the seat back from the predetermined reclined position to the fully reclined position forces the convex portion to slide from a front portion of the channel to a rear portion of the channel to rotate a front edge of the seat suspension about a pivotable coupler to raise a rear portion of the seat suspension.

[0110] According to an embodiment, the predetermined reclined position is about 55.5° relative to a vertical plane.

[0111] According to the present invention, there is provided a seat assembly for a motor vehicle, the seat assembly having: a lower seat structure that further includes a seat frame, a seat suspension disposed adjacent to the seat frame, a pivot rod that laterally extends between rear portions of the seat frame, and a lower seat frame disposed at a rear end of the seat frame, and a seat cushion assembly supported by the seat suspension; a seat back that is pivotable between an upright position and a fully reclined position, the seat back being operatively coupled to the lower seat structure, wherein the seat back has a seat back pivot support at its lower portion, the seat back pivot support being operatively coupled to the lower seat pivot support; and a hip lift mechanism that further includes a hip lift pivot bracket operatively coupled to the pivot rod and rotatably disposed relative to the pivot rod and a slotted linkage mechanism coupled to a lower portion of a seat back frame, wherein the hip lift pivot bracket includes a front rod and a rear portion, wherein the front rod of the hip lift pivot bracket is operatively connected to an edge of the seat suspension via a channel within a flange to raise the edge of the seat suspension upward when the seat back pivots to a predetermined reclined position between the upright position and the fully reclined position, and wherein the rear portion is coupled to the slotted linkage mechanism.

[0112] According to an embodiment, the seat suspension includes a pair of laterally opposed suspension frame members and a suspension cross member extending between the pair of laterally opposed suspension frame members, and the pair of laterally opposed suspension frame members includes bumps for securing a cushion to the pair of laterally opposed suspension members.

[0113] According to an embodiment, an inwardly extending member projects from at least one of the pair of laterally opposed suspension frame members, and wherein the inwardly extending member is coupled to the lower seat structure.

[0114] According to an embodiment, the inwardly extending member includes a circular opening pivotally coupled to a circular member of the lower seat structure.

[0115] According to an embodiment, the seat suspension includes a suspension frame, a fastener coupled to the suspension frame, and a cushion coupled to the suspension frame, wherein the fastener couples the suspension frame to the lower seat structure.

[0116] According to an embodiment, the suspension frame has a rectangular shape, and wherein the suspension frame includes bumps for receiving attachments of the cushion.

[0117] According to an embodiment, the suspension frame includes a glass fiber filled nylon overmolded wire.

[0118] According to an embodiment, the bumps are hook-shaped and made of glass fiber filled nylon.

[0119] According to an embodiment, each of the lower seat structure 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 lower seat structure and the seat back substantially occupy the same horizontal plane.

[0120] According to an embodiment, the linkage mechanism includes a slot and the slot includes an upper end and a lower end, and a rear portion of the hip lift pivot 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 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.

[0121] According to an embodiment, the above invention further features a pair of hip lift mechanisms, wherein each of the pair of hip lift mechanisms is disposed near one of a pair of opposed side lower seat frame members.

[0122] According to an embodiment, the hip lift mechanism raises the seat suspension and the seat cushion assembly between 45 mm and 70 mm between the upright position and the fully reclined position of the seat back.

[0123] According to the present invention, there is provided a seat assembly for forming a substantially horizontal plane of the exposed surfaces of each of a lower seat cushion and a seat back cushion for a seat back, the seat assembly having a lifting mechanism for a rear edge of the lower seat cushion, the lifting mechanism further comprising: a bracket pivotable about a crossbar fixedly mounted on a frame assembly for the seat, the bracket including a front rod operably coupled to the lower seat cushion, and a rear portion; and a connecting rod pinned at a first end to the seat back and at a second end to the rear portion; wherein when the seat back is pivoted to a predetermined reclined position, the front rod first raises the rear edge of the lower seat cushion, and when the seat back is pivoted to a fully reclined position, the rear edge of the lower seat cushion is raised to a substantially horizontal plane.

Claims

1. A lifting mechanism for the edge of a seat cushion, comprising: A main suspension coupled to a crossbar; An auxiliary suspension pivotally coupled to the main suspension, and the auxiliary suspension is slidably connected to a bracket capable of pivoting around the crossbar, wherein the bracket includes a front rod and a rear portion, the front rod is coupled to a channel within a flange of the auxiliary suspension, the rear portion is coupled to a linkage mechanism, wherein a collar portion of the bracket is disposed between the front rod and the rear portion, and wherein the collar portion is capable of pivoting around the crossbar; Wherein the linkage mechanism is coupled to a seat back, and wherein when the seat back pivots to a predetermined inclined position, the front rod raises the edge of the seat cushion.

2. The lifting 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 inclined position, the exposed surfaces of each of the seat cushion and the seat back substantially occupy the same horizontal plane.

3. The lifting mechanism according to claim 2, wherein the linkage mechanism has a slot, the slot including an upper end and a lower end, and wherein the rear portion of the bracket is coupled to 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 inclined position between the upright position and the fully inclined position.

4. The lifting mechanism according to claim 3, wherein pivoting the seat back between the predetermined inclined position and the fully inclined position forces the upper end of the slot against the pin to rotate the bracket, and raises the front rod and the edge of the seat cushion.

5. The lifting mechanism according to claim 4, wherein the front rod is coupled to a protrusion, and wherein the protrusion is slidably received within the channel of the auxiliary suspension.

6. The lifting mechanism according to claim 5, wherein the auxiliary suspension is in a substantially horizontal position in the predetermined inclined position, and wherein pivoting the seat back from the predetermined inclined position to the fully inclined position forces the protrusion to slide from the front of the channel to the rear of the channel to rotate the front edge of the auxiliary suspension around a pivotable coupler to raise the rear portion of the auxiliary suspension.

7. The lifting mechanism according to claim 1, wherein the predetermined inclined position is approximately 55.5° relative to the vertical plane.

8. The lifting mechanism according to claim 1, wherein the auxiliary suspension includes a glass fiber filled nylon overmolded wire.

9. The lifting mechanism according to claim 1, wherein the auxiliary suspension includes a suspension frame, a cushion, and fasteners attaching the cushion to the suspension frame.

10. A vehicle, comprising the lifting mechanism according to any one of claims 1-9.

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