Seat assembly with a compression limiter with a wave-shaped section

Abstract

A seat assembly includes a frame, a seat base layer disposed on the frame, and a compression restraint layer disposed on the seat base layer. The compression restraint layer includes a coil spring portion and a corrugated portion having a curved profile. The corrugated portion includes a plurality of corrugated elements and one or more ribs connecting the corrugated elements. The seat assembly also includes a load distribution layer connected to the compression restraint layer and an adjustment module movable between a rear position and a front position. The adjustment module is configured to move the corrugated portion between a retracted position and an extended position.

Description

[0001] This application is a divisional application of the invention patent application filed on February 22, 2019, with international application number PCT / US2019 / 019237, national application number 201980014465.3, and entitled "Seat assembly with a compression limiter with a wave-shaped portion". Background Technology

[0002] The following description relates to adjustable seat assemblies for automotive applications, office furniture, and leisure vehicle seating.

[0003] Car seat design has traditionally used materials and processes common to different manufacturers. Known seat designs typically include a steel frame, steel suspension, and compression limiters, along with fabric or leather upholstery. Compression limiters are most commonly implemented in car seats as foam layers. Compression limiters are used to distribute reaction forces, disperse stress spikes in the occupant, and provide controlled offset under force, thereby resulting in energy absorption.

[0004] In known automotive seat designs, commonly used foam layers as compression limiters have been found to provide comfort and load distribution observable in pressure map tests. The comfort of a foam seat (i.e., a seat design including foam layers) is determined at least in part by the foam stiffness, thickness, and porosity to control the pressure offset (IFD), a commonly used measure for judging and controlling comfort. The foam material in the foam layers is typically a thermosetting material.

[0005] Some automotive seat designs include additional features such as seat heating and / or cooling systems. Heating and cooling systems may include resistive circuitry (for heating) and associated electrical components (such as armored wiring), a Peltier thermoelectric generator, a blower, a fan, etc. In some seat designs, the vacuum generated by the fan blower can be used through a manifold system permeating the foam layers to draw air and moisture from the occupant, providing a cooling sensation. In some instances, the seat design includes further components configured to reduce the hum, squeaking, and rattling noise (BSR) of these fan blowers.

[0006] Known automotive seat designs can include features that tailor seat comfort and ergonomic functions to individual body shapes and physiques. For example, 4-way and 8-way adjustable seats have become common in the market, and more recently, 33-way adjustable seats have been developed. These types of adjustable seats use electric actuators and air-driven airbags to create joint movement. In some designs, pulse actuation is used to provide a vibratory massage function. Foam layers commonly used in automotive seat design have been found to be suitable for accommodating this adjustability in automotive seat applications while providing appropriate IFD characteristics throughout the entire position range during adjustment.

[0007] However, commonly used foam material layers tend to be bulky and occupy a significant volume within the vehicle's interior. Furthermore, the inherent insulating properties of foam layers necessitate additional design considerations in heating and cooling systems to provide the required level of comfort for seated occupants. Moreover, integrating additional seat components with the foam layer is challenging; these include heating and cooling system components and electrical components such as armor lines, seat adjustment modules, and other auxiliary parts. Typically, these additional components need to be installed beneath or around the foam layer, thus taking up extra volume within the vehicle's interior. Furthermore, commonly used foam materials and chemicals, such as polyurethane foam, may involve the use of conditioning components or other materials that require special handling and / or management during manufacturing. Additionally, in traditional seat designs, polyurethane foam is typically supported by steel or other metal suspension components. However, these materials can be corrosive.

[0008] Therefore, it is desirable to develop alternatives to foam car seat designs to address the aforementioned drawbacks while maintaining or improving as many of the benefits of foam seat designs as possible, such as comfort and adjustability. Summary of the Invention

[0009] In one aspect, the seat assembly includes a frame, a seat base layer disposed on the frame, and a compression restraint layer disposed on the seat base layer. The compression restraint layer includes a coil spring portion and a corrugated portion having a curved profile when the seat assembly is in a non-braking state. The corrugated portion includes a plurality of corrugated elements and one or more ribs connecting the corrugated elements. The seat assembly also includes a load distribution layer connected to the compression restraint layer and an adjustment module movable between a rearward position and a forward position. The adjustment module is configured to move the corrugated portion between a retracted position and an extended position.

[0010] The plurality of waveform elements may include a plurality of first waveform elements and a plurality of second waveform elements. The first waveform elements may be positioned alternately with the second waveform elements. The first and second waveform elements may be movable relative to each other. The first and second waveform elements may be radially offset relative to each other.

[0011] The seat assembly may also include a retaining layer. A compression restraint layer may be disposed between the retaining layer and the load distribution layer. A first waveform element may be connected to the load distribution layer, and a second waveform element may be connected to the retaining layer. The connection to the retaining layer can constrain the waveform layer while allowing the waveform layer to slide radially around the adjustment module.

[0012] The adjustment module may include an actuator and a body. The actuator is configured to move the body to move the adjustment module between a rear position and a front position. The waveform portion may be configured to slide relative to the body to move between a retracted position and an extended position.

[0013] The waveform element can be formed as a linear waveform spring. This waveform element can be made of thermoplastic material.

[0014] According to another embodiment, the compression restraint layer for the seat assembly includes a coil spring portion having multiple coil springs and a corrugated portion having a curved profile. The corrugated portion includes multiple corrugated elements and one or more ribs connecting the corrugated elements.

[0015] The plurality of waveform elements may include a plurality of first waveform elements and a plurality of second waveform elements. The first waveform elements may be positioned alternately with the second waveform elements. The first and second waveform elements may be movable relative to each other. The first and second waveform elements may be radially offset relative to each other. The waveform portion may be movable between a retracted position and an extended position.

[0016] These and other features and advantages of the device will become apparent from the following description, taken in conjunction with the accompanying drawings and the appended claims. Attached Figure Description

[0017] After reading the following detailed description and accompanying drawings, the benefits and advantages of this embodiment will become more apparent to those skilled in the art, wherein:

[0018] Figure 1 This is a bottom perspective view of the seat assembly according to the embodiment described herein;

[0019] Figure 2 yes Figure 1 A top-view perspective of the seat assembly;

[0020] Figure 3 yes Figure 1 and Figure 2 Exploded view of the seat components;

[0021] Figure 4 This is a schematic diagram showing the side of the seat assembly for each layer of the seat;

[0022] Figure 5 This is an illustration of one embodiment of the waveform section, showing a knee support foam replacement surrounding the knee adjustment module in the retracted position;

[0023] Figure 6A and 6B The image shows the rear position according to an embodiment. Figure 6A ) and front position ( Figure 6B The adjustment module;

[0024] Figure 7A and 7B Similar to Figure 6A and 6B An embodiment of the layered seating configuration of the present invention is shown;

[0025] Figure 8A and 8B A perspective view illustrates the concept of a cushioning pad, where, for clarity, the load distribution layer has been omitted, and the compression restraint layer is shown. Figure 8A ); ( Figure 8B A perspective view of the load distribution layer according to an embodiment is shown;

[0026] Figure 9 This is a diagram showing the substantially linear configuration of the processed portion according to an embodiment, and the substantially curved waveform portion installed in the seat assembly.

[0027] Figure 10 This is a perspective view showing the corrugated portion installed at the knee support portion of the seat assembly according to an embodiment;

[0028] Figure 11 This is a top view showing the left and right corrugated portions of the seat assembly configured for individual adjustment according to an embodiment;

[0029] Figure 12 This is a side view of the extrusion limiting layer according to an embodiment, wherein the wave-shaped portion is in the retracted position;

[0030] Figure 13 This is a side view of the extrusion limiting layer according to an embodiment, wherein the wavy portion is in the fully extended position; and

[0031] Figure 14 This is a perspective view of the extrusion limiting layer according to an embodiment, wherein the wave-shaped portion is in the retracted position. Detailed Implementation

[0032] While this disclosure allows for various forms of embodiments, one or more embodiments are shown in the accompanying drawings and will be described below. It should be understood that this disclosure is to be considered illustrative only and is not intended to limit this disclosure to any specific embodiment described or illustrated.

[0033] Figure 1 and Figure 2 These are bottom and top perspective views of the seat assembly 10 according to the embodiments described herein. The seat assembly 10 can be configured as a foam-free seat assembly 10. Figure 3 yes Figure 1 and Figure 2 An exploded view of the seat assembly 10. According to an embodiment, the seat assembly 10 may be an automotive seat assembly designed for installation and use in a vehicle.

[0034] refer to Figure 1-3 The seat assembly 10 typically includes a seat base layer 12, a compression restraint layer 14, and a load distribution layer 16. In one embodiment, the seat base layer 12 may be made of an oriented or partially oriented block copolymer, such as a thermoplastic elastomer (TPE). As will be further described below, the compression restraint layer 14 typically includes a coil spring portion 18 and a corrugated portion 20. The load distribution layer 16 may be arranged above the compression restraint layer 14 and configured to distribute the load from a occupant seated on the seat assembly 10, for example, across the compression restraint layer 14. A retaining layer 22 may be located below at least a portion of the compression restraint layer 14, for example, at the corrugated portion 20.

[0035] Seat assembly 10 may further include a frame 24, an adjustment module 26, and a cushion 28. The frame 24 may be configured to attach to a vehicle body or frame. The adjustment module 26 is configured to adjust the position of the seat components as described below. The cushion 28 may be included in seat assembly 10 to provide a variable reaction spring force that substantially mimics the comfort characteristics of conventional foam seat components (e.g., IFD), but can be formed from thermoplastic material injection molded using known injection molding processes. In some embodiments, the cushion 28 may extend over rigid or angled seat components to limit occupant exposure to these components and improve comfort. In one embodiment, seat assembly 10 may further include a manifold membrane 30. The manifold membrane 30 may be used in conjunction with, for example, a heating and / or cooling system (not shown) for seat assembly 10.

[0036] Figure 4 This is an exploded side view of a seat assembly 10 according to an embodiment, schematically showing some components. In one embodiment, the seat assembly 10 may include a decorative outer layer 32, such as leather or fabric, disposed on a load distribution layer 16. In one embodiment, the seat assembly 10 may include a heating and / or cooling system, which may include, for example, a heating pad 34 disposed below the load distribution layer 16, a ventilation blower 36, and an armor line 38, which may be disposed, for example, below the seat base layer 12 and adjacent to or within the frame 24. However, these components are not limited to such locations.

[0037] According to an embodiment, the spring portion 18 of the compression restraint layer 14 typically extends along a portion of the seat assembly 10 where the occupant sits, where the fundamental vertical component of the occupant's weight is applied to the seat assembly 10. This spring portion 18 may be formed from a plurality of springs extending between the seat base layer 12 and the load distribution layer 16. The springs may be attached to the seat base layer 12 and / or the load distribution layer 16, for example, via multiple snap-fit ​​connections or other suitable attachment mechanisms.

[0038] The corrugated portion 20 of the compression restraint layer 14 can extend generally above the knee support portion of the seat assembly 10, which is designed to support the underside or rear side of the occupant's knees when the occupant is seated. Therefore, in at least one configuration, the corrugated portion 20 can extend approximately in a linear spiral shape around the center of curvature. For example, as... Figure 4 As shown, in the side view, the waveform section 20 can be extended as a generally C-shaped curved segment.

[0039] In one embodiment, the adjustment module 26 may be a knee support module configured to adjust the position of the knee support portion of the seat assembly 10. For example, as further described below, the adjustment module 26 may be actuated to move the waveform portion 20. In one embodiment, the adjustment module 26 includes an actuator 40 operably connected to a body 42. The actuator 40 may be operated to drive the body 42 to adjust the position of the knee support portion.

[0040] Figure 5 This is an enlarged perspective view of the seat assembly 10, showing a compression restraint layer 14 according to an embodiment, which includes a corrugated portion 20 at the knee support portion. The corrugated portion 20 may be substantially linear in its overall shape, for example, extending in the width direction 'W' of the seat assembly 10. The corrugated portion 20 includes a plurality of corrugated elements 44, 46. In one embodiment, the plurality of corrugated elements includes one or more first corrugated elements 44 and one or more second corrugated elements 46. In one embodiment, a plurality of first and second corrugated elements 44, 46 are provided, and the individual first and second corrugated elements 44, 46 are alternately positioned relative to each other along a length direction or a curvature direction. In one embodiment, the first and second corrugated elements 44, 46 may be offset or staggered relative to each other in a radial or thickness direction. For example, the first corrugated element 44 may be positioned relatively outward (i.e., closer to the outside of the seat assembly 10 or the load support layer 16), and the second corrugated element 46 may be positioned relatively inward (i.e., closer to the retaining layer 22 or the adjustment module 26). In one embodiment, the corrugated elements 44, 46 may be made of a thermoplastic material.

[0041] In one embodiment, the waveform elements 44 and 46 of the first and second waveform elements can be formed as separate, individual springs, and can include, for example, along their respective lengths (the lengths of the waveform elements 44 and 46 are within...). Figure 5 One or more wave-like or undulating structures are formed by the seat assembly 10 extending in the width direction W. That is, the wave elements 44, 46 can be formed as substantially linear wave springs. In another embodiment, these individual wave elements 44, 46 may include cup-shaped portions or may be substantially flat. These wave elements 44, 46 can be connected to each other by one or more ribs 48. The ribs 48 are configured to bend when needed, for example, during adjustment of the knee support portion as further described below, thereby allowing movement of the first and second wave elements 44, 46.

[0042] In one embodiment, the first waveform element 44 may be connected to the load distribution layer 16 via one or more snap-fit ​​connections or other suitable connections. For example, the first waveform element 44 may include one or more trunnions 50 or other suitable protrusions configured to snap-fit ​​with the underside of the load distribution layer 16. Similarly, the second waveform element 46 may be connected to the retaining layer 22 via one or more trunnions (not shown) or similar suitable protrusions configured to snap-fit ​​with the retaining layer 22. However, this disclosure is not limited to such snap-fit ​​connections, and other suitable connections are contemplated.

[0043] Figure 6A and 6B This is a side view of the seat assembly 10 according to an embodiment of the present disclosure, wherein the adjustment module 26 is in the rear (or retracted) position. Figure 6A ) and front (or extended) position ( Figure 6B ).like Figure 6A and 6B As shown, in order to adjust the position of the knee support portion of the seat assembly 10, the actuator 40 is operated to move the main body 42 from... Figure 6A The position in the middle moves outward. Figure 6B The position in the middle allows the length of the knee support portion to be extended. Conversely, the actuator 40 can be operated to move the body 42 from... Figure 6B The position in the middle moves inward Figure 6A The position is adjusted to reduce the length of the knee support portion.

[0044] Figure 7A and 7B This is a side view of the seat assembly 10, which has a retainer 22 positioned above the adjustment module 26 and a compression limiting layer 14 (including a wave-shaped portion 20). See also Figure 6A , 6BAccording to embodiments of this disclosure, the adjustment module 26 is in the rear (retracted) position. Figure 7A ) and front (extended) position ( Figure 7B Including the first and second waveform elements 44 and 46 (see...) Figure 5 The waveform portion 20 is configured such that movement of the adjustment module 26 from a rear position to a front position (and vice versa) causes the waveform portion 20 to slide along the surface of the body 42 without constraining, affecting, or relaxing the desired or customer-specified IFD requirements. Therefore, with the waveform portion 20 of the embodiment described herein, the compression restraint layer 14 can provide consistent comfort in all positions of the adjustment module 26. The retaining layer 22 is configured to slide relative to the surface of the body 42 having the waveform portion 20.

[0045] The sliding of the waveform section 20 is provided by the arrangement of first and second waveform elements 44 and 46, which are arranged separately from each other and configured to move independently of each other. Therefore, during the sliding of the waveform section 20, the individual first and second elements 44 and 46 can move relative to each other.

[0046] See also Figure 7A and 7B When the adjustment module 26 is in the rear position, the waveform section 20 is in the retracted position. Figure 7A In the retracted position, the waveform section 20 has a substantially curved profile in the side view. Moving the adjustment module 26 to the forward position moves the waveform section 20 to the extended position. Figure 7B According to one embodiment, in the extended position, the waveform portion 20 is at least partially straightened in a side view, for example, moving from a curved profile toward a linear profile. As a result of the sliding of the waveform portion 20 relative to the body 42, the free end 52 of the waveform portion 20 changes position relative to the surface of the body 42. Conversely, the movement of the adjustment module 26 from the front position to the rear position causes the waveform portion 20 to move from the extended position to the retracted position. Furthermore, the waveform shape and load displacement can be maintained throughout the adjustment process.

[0047] Figure 8A and 8B This is a perspective view showing a seat assembly 10 according to an embodiment described herein, wherein Figure 8A The load distribution layer 16 was removed to more clearly show the compression restraint layer 14, while... Figure 8BA load distribution layer 16 is installed. In one embodiment, the load distribution layer 16 includes a plurality of shape segments 54 connected to each other. In one embodiment, each shape segment 54 may be connected to the compression restraint layer 14, for example, by a snap-fit ​​connection. In this way, the pressure applied to the load distribution layer 16 can be distributed across the shape segments 54 and the compression restraint layer 14 to obtain the desired IFD characteristics and pressure profile.

[0048] Figure 9 This diagram shows both the finished waveform section 20 in a basically linear configuration and the waveform section 20 in a basically curved configuration that has been mounted on the seat assembly 10. Figure 9 As shown, in one embodiment, the thickness of the second waveform element 46 may gradually decrease toward the free end 52 of the waveform portion 20.

[0049] Figure 10 This is a perspective view showing the wave-shaped portion 20 installed at the knee support portion of the seat assembly 10 according to an embodiment.

[0050] Figure 11 This is a top view showing left and right corrugated portions 20L, 20R configured for individual adjustment on the seat assembly 10 according to an embodiment. In one embodiment, the seat assembly 10 may include an individually adjustable left knee support portion and a right knee support portion. For this purpose, separate left and right corrugated portions 20L, 20R can be provided. Although in Figure 11 Although not shown, it should be understood that separate left adjustment module 26 and right adjustment module 26 may also be provided, and the left adjustment module and right adjustment module can operate independently of each other.

[0051] Figure 12 This is a side view of the compression limiting layer 14 according to the embodiment described herein, wherein the wave portion 20 is in the retracted position. Figure 13 This is a side view of the compression restraint layer 14 according to the embodiment described herein, wherein the wave portion 20 is in the fully extended position. As described above, and as... Figure 12 As shown, in the retracted position, the wave portion 20 can have a substantially curved profile and can have a linear spiral shape in the side view. In the fully extended position, as... Figure 13As shown, the waveform section 20 can be configured as a substantially linear or planar shape. Waveform elements 44, 46 are configured to move during adjustment such that stretching or contraction of the decorative outer layer 32 is substantially limited or prevented throughout the adjustment process, while simultaneously providing a cushioning effect and the desired IFD compliance. In one embodiment, due to the sliding of waveform elements 44, 46, the length 'L' of the waveform section 20, measured along a straight line or curve, can be substantially constant as the waveform section 20 moves between a retracted position and an extended position. In one embodiment, this feature can be achieved at least in part through the independent relative movement of the individual waveform elements 44, 46 during adjustment.

[0052] Figure 14 This is a perspective view of the compression limiting layer 14 according to an embodiment, wherein the waveform portion 20 is in the retracted position. As described in the above embodiment, the first and second waveform elements 44, 46 can be positioned alternately and staggered or interleaved relative to each other.

[0053] In the above embodiments, the waveform section 20 is designed to maintain a common straight length at the Class A interface where the outer decorative layer 32 contacts the load distribution layer 16. This straight length design allows the waveform section to fold and expand (i.e., retract and extend) during adjustment without causing the outer decorative layer 32 to wrinkle or be overstretched. The straight-line positioning length also allows the manufacturer to remove and replace the outer decorative layer 32 and / or use the load distribution layer 16 as the occupant interface.

[0054] The seat assembly 10 of the embodiment described herein, wherein the conventional foam layer is replaced by an extrusion-restricted layer 14 including a corrugated portion 20, allows for seat production at a reduced cost, occupies a smaller volume, provides a more breathable occupant seating interface, avoids fluid absorption, is easy to clean, and can reduce emissions by using inert thermoplastic materials.

[0055] The embodiments described herein, including the compression-limiting layer 14 with a wave-like portion 20, also allow for changes in the seat's thickness and profile shape throughout the seat adjustment process. The seat shape utilizing suspension tensioning members is conventionally limited to a one-dimensional (1D) variable profile by altering the shape of the tensioning frame. However, when using only the suspension, the two-dimensional (2D) seat surface profile is already limited. Materials providing compression-limiting functionality and physical thickness, such as foam or disc springs, can provide seat designers with a 2D profile, but material limitations arise, for example, when wrapped around the actuation radius in the knee support portion. Figure 5 , Figure 6A , Figure 6B , Figure 7A and Figure 7B As shown, the waveform section 20 described herein allows for an actuator travel of several millimeters while maintaining seat shape and IFD comfort conformability.

[0056] With its wide-range adjustment mechanism, the waveform section 20 can also adapt to different user needs. For example, the force offset or elastic ratio can be adjusted by adjusting the waveform element width, waveform element shape (flat shape vs. cup shape), waveform element material, modal performance, top (outer) wave height vs. bottom (inner) wave height, waveform spacing, polarity waveform frequency (wave number), and other inputs.

[0057] It has been found that embodiments of the seat assembly 10 described herein are capable of providing an IFD compliant design that performs in accordance with or exceeds the performance of foam materials used in most or all adjustment positions in conventional automotive seat applications. Figures 6A-6B and Figures 7A-7B The highlighted adjustment shows an example of the range of actuation adjustment (e.g., 50mm-100mm range) for an occupant located in a 33-way adjustable seat.

[0058] It should also be understood that various changes and modifications to the embodiments disclosed herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of this disclosure and without diminishing its intended advantages. Therefore, the appended claims are intended to cover such changes and modifications. It should also be understood that various features from the embodiments shown above and in the accompanying drawings can be combined with other embodiments described herein and shown in the accompanying drawings.

Claims

1. A seat assembly, comprising: frame; A seat base layer, wherein the seat base layer is disposed on the frame; A compression restraint layer is disposed adjacent to the seat base layer, the compression restraint layer including a corrugated portion forming knee support; A load distribution layer connected to the compression restraint layer; and An adjustment module, movable between a rear position and a front position and configured to move the waveform portion between a retracted position and an extended position, The waveform portion includes one or more first waveform elements formed as springs and one or more second waveform elements formed as springs, wherein the first waveform elements are offset from the second waveform elements in the radial direction.

2. The seat assembly according to claim 1, wherein, At least one of the first waveform elements forms a cup shape in the extended position and a flat shape in the retracted position.

3. The seat assembly of claim 1, wherein the compression restraint layer further includes a coil spring portion, the coil spring portion comprising a plurality of coil springs.

4. The seat assembly of claim 3, wherein the plurality of coil springs extend between the seat base layer and the load distribution layer.

5. The seat assembly of claim 4, wherein the plurality of coil springs are attached to the seat base layer or the load distribution layer by a plurality of snap-fit ​​connections.

6. The seat assembly of claim 1, wherein the waveform portion has a length measured along a straight line or curve, and the length is substantially constant in both the retracted position and the extended position.

7. The seat assembly of claim 1, wherein the first waveform element is a separate, individual spring having a length extending along the width direction, and the first waveform element includes one or more waveform structures formed along the respective length of the first waveform element.

8. The seat assembly of claim 7, wherein the first waveform element is formed as a generally linear waveform spring.

9. The seat assembly of claim 1, wherein the wave portion has a curved profile in the retracted position and a linear profile in the extended position.

10. The seat assembly of claim 1, wherein the first set of trunnions connects the waveform portion to the load distribution layer.

11. The seat assembly of claim 10, wherein the retaining layer is located between the waveform portion and the adjustment module, and a second set of trunnions connects the waveform portion to the retaining layer.

12. The seat assembly of claim 1, wherein the first waveform element is closer to the load distribution layer than the second waveform element.

13. The seat assembly of claim 1, wherein the first waveform element and the second waveform element are configured to move or slide relative to each other.

14. The seat assembly of claim 1, wherein the force offset or elastic ratio of the first waveform element can be adjusted by adjusting the width of the waveform element, the shape of the waveform element between a flat shape and a cup shape, the waveform height, the waveform spacing, or by changing the wave number including the first waveform element.

15. The seat assembly of claim 1, wherein the first waveform element and the second waveform element comprise one or more waveform structures or undulating structures formed along their respective lengths, the lengths of the first waveform element and the second waveform element extending in the width direction of the seat assembly.

Images