Seat-mounted knee bolsters

Abstract

A knee bolster assembly for a vehicle seat includes a knee bolster movably mounted adjacent the vehicle seat. The knee bolster is selectively movable between a first position in which a passenger can access the vehicle seat and a second position in which the knee bolster is positioned directly in front of a seat pan of the vehicle seat such that a passenger seated in the vehicle seat has his or her legs positioned between the seat pan and the knee bolster. The knee bolster is used to prevent a passenger in the vehicle seat from sliding forward out of the seat and to limit any hyperextension of the passenger's lower extremities due to forward inertia. An energy absorbing device is adapted to absorb energy when the knee or leg of a passenger in the vehicle seat impacts the knee bolster.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a knee bolster for a vehicle seat. Knee bolsters are commonly used as interior components of motor vehicles and are typically mounted on the dashboard of a motor vehicle. During a frontal impact of a motor vehicle, the knee bolster provides a first contact surface for the knees of a seated passenger, helping to cushion and guide the knees. When an impact occurs, a sliding phenomenon occurs, causing the lower body of a driver or passenger seated on a vehicle seat to be forcibly pushed down due to inertia, below the dashboard. In this case, the knees of the driver or passenger seated on the vehicle seat can be pushed forward into the vehicle frame. Furthermore, due to the sliding phenomenon, the upper body of the vehicle driver or passenger can easily move forward. BACKGROUND

[0002] Even in vehicles with a collision airbag, a vehicle passenger can "slide" under the inflating airbag. A knee bolster is installed in front of the dashboard to absorb the impact on the driver or passenger in the event of a frontal collision. This can prevent or stop the passenger from sliding under the inflating airbag. Thereafter, the knee bolster deforms or is crushed under load, absorbing energy and minimizing the force acting on the passenger's legs, thereby reducing the impact on the passenger's knees, while preventing or reducing the effects of the sliding phenomenon. The knee bolster also provides energy management for the lower body of the passenger and transfers the load to other components, such as energy absorbing brackets and support structures of the dashboard.

[0003] In an autonomous vehicle, in order to effectively use such a knee bolster installed on the dashboard, the vehicle seat must not be placed near the dashboard. Therefore, while the current vehicle knee bolster achieves the intended purpose, there is a need for a new and improved knee bolster assembly to provide a knee bolster that is movably mounted to a vehicle seat. SUMMARY

[0004] In several aspects of the present disclosure, a knee bolster assembly for a vehicle seat includes a knee bolster movably mounted in the vicinity of the vehicle seat, the knee bolster being selectively movable between a first position and a second position, the first position allowing ingress and egress of a passenger to the vehicle seat, the second position positioning the knee bolster directly in front of a seat surface of the vehicle seat such that a leg of a passenger seated within the vehicle seat is positioned between the seat surface of the vehicle seat and the knee bolster, the knee bolster being adapted to prevent the passenger seated within the vehicle seat from sliding forward out of the seat and limit hyperextension of the lower extremities due to forward inertia, and an energy absorbing device adapted to absorb energy when a knee or leg of the passenger seated within the vehicle seat impacts the knee bolster.

[0005] In another aspect, the knee bolster includes a rigid reaction plate and a cushion member attached to a surface of the rigid reaction plate facing a seat pan of the vehicle seat when the knee bolster is in the second position and made of a deformable material adapted to absorb energy when a knee of an occupant in the vehicle seat exerts a generally vertically directed force on the knee bolster.

[0006] In another aspect, the knee bolster assembly further includes a locking mechanism adapted to secure the knee bolster in the second position and at least one of a manual release and an automatic release adapted to selectively release the locking mechanism.

[0007] In another aspect, the knee bolster assembly further includes an external marker adjacent to the locking mechanism adapted to provide an indication of a location of the locking mechanism to guide a mechanic or first responder to the location of the locking mechanism.

[0008] In another aspect, the knee bolster is pivotally movable between the first position and the second position.

[0009] In another aspect, the energy absorbing device includes a torsion bar positioned between the knee bolster and a structure of the vehicle seat and an adjacent vehicle seat and interconnecting the knee bolster and one of the structure of the vehicle seat and the adjacent vehicle seat, the knee bolster being pivotally movable about an axis of the torsion bar between the first position and the second position, wherein the force exerted by the knee of the occupant on the knee bolster is at least partially absorbed by the torsion bar when the knee bolster is locked in the second position.

[0010] In another aspect, the knee bolster is slidably movable between the first position and the second position.

[0011] In another aspect, the knee bolster is adapted to be manually moved between the first position and the second position by an occupant seated in the vehicle seat.

[0012] In another aspect, the knee bolster assembly further includes a first motor element to move the knee bolster between the first position and the second position, wherein the knee bolster is automatically moved from the first position to the second position in response to at least one of a plurality of first predetermined conditions and from the second position to the first position in response to at least one of a plurality of second predetermined conditions.

[0013] In another aspect, the knee bolster is automatically moved from the first position to the second position only when an occupant restraint system for an occupant seated in the vehicle seat is engaged.

[0014] In another aspect, the knee bolster includes a first portion movably mounted proximate a first side of the vehicle seat and a second portion movably mounted proximate a second side of the vehicle seat, each of the first and second portions movable between a first position in which a passenger is able to ingress and egress the vehicle seat and a second position in which the first and second portions are positioned directly in front of a seat pan of the vehicle seat such that a leg of a passenger seated in the vehicle seat is positioned between the seat pan of the vehicle seat and the first and second portions of the knee bolster.

[0015] In another aspect, when in the second position, the knee bolster is adapted to selectively translate or rotate relative to the seat pan of the vehicle seat at least one of.

[0016] In another aspect, the knee bolster assembly further includes a second motor element adapted to move the knee bolster in at least one of a translational motion and a rotational motion relative to the seat pan of the vehicle seat, the knee bolster being adapted to automatically move proximate the seat pan of the vehicle seat and reduce a distance between a knee of a passenger and the knee bolster in response to a detection of an impending collision.

[0017] In another aspect, the energy absorbing device is adapted to cause the knee bolster to move in a generally vertical dampened motion when a knee of a passenger in the vehicle seat exerts a vertical force on the knee bolster.

[0018] In several aspects of the disclosure, a knee bolster assembly for a vehicle seat includes a knee bolster adapted to prevent a passenger of the vehicle seat from sliding forward out of the seat and to avoid overextension of the lower limbs due to forward inertia, the knee bolster having a first portion movably mounted proximate a first side of the vehicle seat and a second portion movably mounted proximate a second side of the vehicle seat / adjacent vehicle structure, each of the first and second portions including a reaction plate selectively movable between a first position and a second position, the first position enabling ingress and egress of the passenger from the vehicle seat, the second position positioning the first and second portions directly in front of a seat pan of the vehicle seat such that the legs of the passenger seated in the vehicle seat are positioned between the seat pan and the first and second portions, a locking mechanism adapted to secure the knee bolster in the second position, one of a manual release and an automatic release adapted to selectively release the locking mechanism, an energy absorbing device adapted to absorb energy when the knee bolster is secured in the second position by the locking mechanism and the legs of the passenger in the vehicle seat impact the first and second portions of the knee bolster, a first motor element in the first portion of the knee bolster for moving the first portion of the knee bolster between the first and second positions, a first motor element in the second portion of the knee bolster adapted to move the second portion of the knee bolster between the first and second positions, wherein the first motor elements are adapted to automatically move the first and second portions of the knee bolster from the first position to the second position when a passenger restraint system adapted for the passenger seated in the vehicle seat is engaged and in response to at least one of a plurality of first predetermined conditions, and to automatically move the first and second portions of the knee bolster from the second position to the first position in response to at least one of a plurality of second predetermined conditions.

[0019] In another aspect, each of the first and second portions of the knee bolster includes a second motor element, each of the first and second portions of the knee bolster is selectively movable horizontally relative to the seat pan of the vehicle seat when the first and second portions of the knee bolster are in the second position, the second motor elements in the first and second portions of the knee bolster are adapted to automatically move the first and second portions of the knee bolster closer to the seat pan of the vehicle seat and to reduce a distance between the knees of the passenger and the knee bolster.

[0020] In another aspect, each of the first and second portions of the knee bolster is pivotally movable between the first and second positions, the energy absorbing device in the first and second portions includes a torsion bar, the first and second portions of the knee bolster are pivotally movable about an axis of the torsion bar between the first and second positions, wherein a force exerted on the knee bolster by the knees of the passenger is at least partially absorbed by the torsion bar when the knee bolster is locked in the second position.

[0021] In several aspects of the disclosure, a vehicle seat including a knee bolster assembly includes a knee bolster movably mounted proximate the vehicle seat, the knee bolster including a reaction plate and being selectively movable between a first position in which a passenger is able to ingress and egress the vehicle seat and a second position in which the knee bolster is positioned directly in front of a seat pan of the vehicle seat such that a passenger seated in the vehicle seat has legs positioned between the seat pan of the vehicle seat and the knee bolster, the knee bolster assembly further adapted to prevent the passenger seated in the vehicle seat from sliding forward out of the seat and to limit overextension of the passenger's lower extremities due to forward inertia, a locking mechanism for securing the knee bolster in the second position, one of a manual release and an automatic release for selectively releasing the locking mechanism, an energy absorbing device adapted to absorb energy when a knee of the passenger seated in the vehicle seat exerts a force in a vertical direction on the knee bolster, and a first motorized element adapted to move the knee bolster between the first position and the second position, wherein the knee bolster is adapted to automatically move from the first position to the second position in response to at least one of a plurality of first predetermined conditions and to move from the second position to the first position in response to at least one of a plurality of second predetermined conditions.

[0022] In another aspect, the vehicle seat further includes a second motorized element, wherein the knee bolster is selectively horizontally movable relative to the seat pan of the vehicle seat when in the second position, the second motorized element adapted to automatically move the knee bolster closer to the seat pan of the vehicle seat and to reduce a distance between the knee of the passenger.

[0023] In another aspect, the knee bolster includes a first portion movably mounted proximate a first side of the vehicle seat and a second portion movably mounted proximate a second side of the vehicle seat, each of the first and second portions being selectively movable between a first position in which a passenger is able to ingress and egress the vehicle seat and a second position in which the first and second portions are positioned directly in front of a seat pan of the vehicle seat such that a passenger seated in the vehicle seat has legs positioned between the seat pan of the vehicle seat and the first and second portions of the knee bolster.

[0024] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0025] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 Perspective view of a vehicle seat having a knee bolster assembly in accordance with an exemplary embodiment;

[0027] Figure 2 is Figure 1 portion of Fig.Figure 1 "in Figure 2 As shown in the image;

[0028] Figure 3 A side view of a passenger sitting in a vehicle seat with knee pads, according to an exemplary embodiment of the present disclosure;

[0029] Figure 4 A side view of a passenger sitting in a vehicle seat with knee pads according to an exemplary embodiment of the present disclosure, wherein the passenger is forced to lean forward into the knee pads;

[0030] Figure 5 A cross-sectional view of a knee pad having a reaction plate and a liner member according to an exemplary embodiment;

[0031] Figure 6 This is a schematic diagram of a locking mechanism according to an exemplary embodiment;

[0032] Figure 7 A perspective view of a one-piece knee pad rotating about the longitudinal axis between the first and second positions;

[0033] Figure 8 A perspective view of a support shaft including a toothed extension and a torsion bar according to an exemplary embodiment;

[0034] Figure 9 For use Figure 7 A schematic diagram of the locking mechanism for the vehicle seat and knee pads is shown.

[0035] Figure 10 A schematic diagram of a vehicle seat with a seat cushion according to an exemplary embodiment, wherein the first and second portions rotate about a longitudinal axis between the first and second positions;

[0036] Figure 11 A schematic diagram of a vehicle seat with a seat cushion according to another exemplary embodiment, wherein the first and second portions rotate about a longitudinal axis between the first and second positions;

[0037] Figure 12 A schematic diagram of a vehicle seat with a seat cushion according to another exemplary embodiment, wherein the first and second portions rotate about a transverse axis between the first and second positions;

[0038] Figure 13 for Figure 12 A perspective view of the first part of the knee pad shown;

[0039] Figure 14 A schematic diagram of a vehicle seat having a knee pad that moves horizontally back and forth relative to the seat surface.

[0040] Figure 15a perspective view of a vehicle seat having a knee bolster including a first motor element, a second motor element, and an energy absorbing device;

[0041] Figure 16 a schematic top view of a passenger within a vehicle seat having a knee bolster including an energy absorbing device of deformable material;

[0042] Figure 17 a schematic top view as shown in Figure 16 where the knee bolster has been moved forward and the energy absorbing material has been compressed; and

[0043] Figure 18 a schematic view according to

[0044] The drawings are not necessarily to scale, with some features possibly exaggerated or minimized for clarity. In certain instances, well-known parts, systems, materials or methodologies have not been described in detail in order to avoid obscuring the application. Accordingly, the particular structure and functions set forth in this disclosure are not to be interpreted as limiting but merely as a representative basis for a broad application of the principles of the present disclosure. DETAILED DESCRIPTION

[0045] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, summary or the following detailed description. It is to be understood that the same or equivalent parts and features shown in the drawings are identified by the same or similar reference characters. As used herein, the term module refers to any hardware, software, firmware, electronic control components, processing logic, and / or processor device used alone or in any combination thereof, including but not limited to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functionality. Although the drawings shown herein depict examples with certain elements arranged in certain configurations, additional intervening elements, devices, features or components can be present in actual embodiments. It is also to be understood that the drawings are only schematic and can not be to scale.

[0046] As used herein, the term "vehicle" is not limited to automobiles. While the present technology is primarily described herein in relation to automobiles, the present technology is not limited to automobiles. These concepts can be used in a wide variety of applications, such as connections with aircraft, watercraft, other vehicles, and consumer electronics components.

[0047] Referring to Figure 1, a vehicle seat 10 equipped with a knee bolster assembly 12 according to the present disclosure is shown. The vehicle seat 10 includes a seat pan 14 on which a passenger of the vehicle sits. The knee bolster assembly 12, which includes a knee bolster 16, is movably mounted to the vehicle seat 10 or an adjacent vehicle structure. The knee bolster 16 is selectively movable between a first position and a second position. As shown by the solid line Figure 1 As shown by the hatched line, when the knee bolster 16 is in the first position, the passenger is able to ingress and egress the vehicle seat 10. As shown by the Figure 1 As shown by the hatched line, when the knee bolster 16 is in the second position, the knee bolster 16 is directly in front of the seat pan 14 of the vehicle seat 10 such that the legs of a passenger seated within the vehicle seat 10 are positioned between the seat pan 14 of the vehicle seat 10 and the knee bolster 16. As shown by the Figure 1 As shown, the knee bolster 16 includes a tray portion 18 that provides a work surface for the passenger when the knee bolster 16 is in the second position.

[0048] The knee bolster 16 is adapted to prevent the passenger within the vehicle seat 10 from sliding forward out of the vehicle seat 10 and to limit overextension of the lower limbs due to forward inertia. Referring to Figure 3 wherein there is no forward inertia acting on the passenger 20 within the vehicle seat 10 and the knee bolster 16 is in the second position directly in front of the knees 22 of the passenger 20. Referring to Figure 4 In the event of a frontal impact or sudden application of the vehicle brakes, the forward inertia will force the passenger 20 to surge forward relative to the vehicle seat 10 as indicated by arrow 24. In the event that the passenger 20 is restrained within the vehicle seat by a passive restraint system, such as a seat belt 26, the torso of the passenger 20 will cease forward movement. However, the inertia can cause the lower legs 28 of the passenger 20 to swing upward as indicated by arrow 30.

[0049] As the passenger 20 moves forward, the knees 22 of the passenger 20 will come into contact with the knee bolster 16, wherein the knee bolster 16 is able to prevent further forward movement of the passenger 20. Additionally, the knee bolster 16 prevents the lower portions of the passenger's legs 28 from moving upward. The knee bolster 16 further includes an energy absorbing device 32 that is adapted to absorb energy as the knees 22 and lower legs 28 of the passenger 20 within the vehicle seat 10 impact the knee bolster 16.

[0050] Referring to Figure 5 In the exemplary embodiment, the knee bolster 16 includes a rigid reaction plate 34 and the energy absorbing device 32 includes a cushioning member 36. The cushioning member 36 is attached to the rigid reaction plate 34 facing a front 38 of the seat pan 14 of the vehicle seat 10 when the knee bolster 16 is in the second position. Thus, the knees 22 and lower legs 28 of the passenger 20 within the vehicle seat 10 come into contact with the cushioning member 36 that cushions the impact and absorbs energy. The cushioning member 36 is made of a deformable material that is adapted to absorb energy as the knees 22 and lower legs 28 of the passenger 20 within the vehicle seat 10 exert a vertically directed force on the knee bolster 16. The cushioning member 36 can be made of a material such asFigure 5 The foam, honeycomb design, or any combination of these of the crushable plastic design shown is made.

[0051] In an exemplary embodiment, as Figure 1 The knee bolster assembly 12 includes a locking mechanism 40 as Figure 6 shown and a manual release 42 as Figure 2 and Figure 13 shown, the locking mechanism 40 adapted to secure the knee bolster 16 in the second position, the manual release 42 adapted to selectively release the locking mechanism 40 through a mechanical interface to the locking mechanism 40. Figure 1

[0052] Referring to Figure 1 The knee bolster 16 is slidably movable between the first and second positions as indicated by arrows 44, 46. The knee bolster 16 includes lateral rails 48 that slidably engage rails 50 on the vehicle seat 10 or adjacent vehicle structure. The locking mechanism 40 is mounted to the knee bolster assembly 12 and engages the rails 50 on the vehicle seat 10 to prevent the knee bolster 16 from sliding on the rails 50, thereby locking the knee bolster 16 in the second position. The locking mechanism 40 can include elements that frictionally engage or interlock with the rails 50, the vehicle seat 10, or adjacent vehicle structure to prevent movement of the knee bolster 16 from the second position. Alternatively, the locking mechanism 40 can be attached to the vehicle seat 10, adjacent vehicle structure, and frictionally engage or interlock with the rails 50 or the knee bolster assembly 12.

[0053] Referring to Figure 6 In an exemplary embodiment, the locking mechanism 40 includes a ratchet mechanism 52 that provides a front stop to prevent movement of the knee bolster 16 from the second position. The ratchet mechanism 52 includes a rotating gear 54 that is geared through a rack and pinion (not shown) to rotate with movement of the knee bolster 16 between the first and second positions. The rotating gear 54 includes teeth 56 that engage a pawl 58 that is biased by a spring 60 to engage the teeth 56 of the rotating gear 54. As the knee bolster 16 moves from the first position to the second position as indicated by arrow 46, the pawl 58 rotates the rotating gear 54 in a first direction as indicated by arrow 62. Once the knee bolster is in the second position, the pawl 58 prevents the rotating gear 54 from rotating in a second direction as indicated by arrow 64, thereby preventing movement of the knee bolster from the second position to the first position.

[0054] The manual release 42 disengages the locking mechanism 40 and moves the knee bolster 16 from the second position to the first position. In Figure 6 ​In the exemplary embodiment shown, the manual release 42 allows the spring 60 to be manually overridden and push the pawl 58 out of engagement with the teeth 56 of the rotating gear 54, as indicated by arrow 66, thereby causing the rotating gear 54 to rotate in a second direction, as indicated by arrow 64, and causing the knee bolster 16 to move from the second position to the first position, as indicated by arrow 44. The manual release 42 can push the pawl 58 out of the plane of the rotating gear 54, or rotate the pawl 58 out of the way of the rotating gear 54, as indicated by arrow 68, such that the pawl 58 is no longer in engagement with the teeth 56 of the rotating gear 54. The manual release 42 can be a simple mechanical actuator, or alternatively, an electronic or automatic release, such as a solenoid or switch actuated electronic actuator.

[0055] In the exemplary embodiment shown in FIG. 1, the knee bolster 16 is pivotally mounted to the vehicle seat 10 and is movable between a first position, as shown in phantom in FIG. 1, and a second position, as shown in solid in FIG. 1. In the first position, the knee bolster 16 is positioned to protect the lower leg of an occupant of the vehicle seat 10. In the second position, the knee bolster 16 is positioned to protect the upper leg of an occupant of the vehicle seat 10. Figure 2 and Figure 13 In the exemplary embodiment shown in FIG. 1, the knee bolster 16 includes external indicia 70 adjacent the locking mechanism 40 that is adapted to indicate the position of the locking mechanism 40. The external indicia 70 identifies the cutaway region, such that in the event of a mechanical failure, loss of power, or damage to the manual or electronic / automatic release 42 during a crash, the locking mechanism 40 can be disengaged. In this manner, a first responder or operator of the vehicle can quickly identify the position of the locking mechanism 40 and where to cut the locking mechanism or the knee bolster or seat adjacent the locking mechanism, such that the first responder can release the knee bolster 16, move the knee bolster 16 from the second position to the first position, or completely remove the knee bolster and free the occupant in the event of a mechanical failure of the manual release 42 during a crash.

[0056] Referring to Figure 7 In another exemplary embodiment, the knee bolster 16' is pivotally movable between a first position and a second position. The knee bolster 16' is rotatably supported on a support shaft 72 and is rotatable about a generally vertical axis 73 between a first position, as shown in phantom in FIG. 2, and a second position, as shown in solid in FIG. 2. In another exemplary embodiment, as shown in FIG. 3, the energy absorbing device 32 further includes a torsion bar 74 positioned between and interconnecting the knee bolster 16 and the vehicle seat 10 or adjacent vehicle structure. Here, the torsion bar 74 is incorporated within the support shaft 72 that supports the knee bolster 16. Figure 7 Figure 7 In another exemplary embodiment, as shown in FIG. 3, the energy absorbing device 32 further includes a torsion bar 74 positioned between and interconnecting the knee bolster 16 and the vehicle seat 10 or adjacent vehicle structure. Here, the torsion bar 74 is incorporated within the support shaft 72 that supports the knee bolster 16. Figure 8

[0057] Continuing to refer to FIG. 3, the support shaft 72 includes an extension 76 that includes teeth 78 and a torsion bar 74. The bottom 80 of the torsion bar 74 is fixedly attached to the structure of the vehicle seat 10 or adjacent vehicle structure. The knee bolster 16' is supported on the support shaft 72 and is rotatable relative to the support shaft 72 about a central axis 82 of the support shaft 72. Figure 8 Continuing to refer to FIG. 3, the support shaft 72 includes an extension 76 that includes teeth 78 and a torsion bar 74. The bottom 80 of the torsion bar 74 is fixedly attached to the structure of the vehicle seat 10 or adjacent vehicle structure. The knee bolster 16' is supported on the support shaft 72 and is rotatable relative to the support shaft 72 about a central axis 82 of the support shaft 72.

[0058] Continuing to refer to FIG. 3, the support shaft 72 includes an extension 76 that includes teeth 78 and a torsion bar 74. The bottom 80 of the torsion bar 74 is fixedly attached to the structure of the vehicle seat 10 or adjacent vehicle structure. The knee bolster 16' is supported on the support shaft 72 and is rotatable relative to the support shaft 72 about a central axis 82 of the support shaft 72. Figure 9 ​​In the exemplary embodiment, the locking mechanism 40 includes a ratchet mechanism 84 that provides a front stop to prevent the knee bolster 16' from moving from the second position. The ratchet mechanism 84 includes a pawl 86 positioned within the knee bolster assembly 12 that is biased by a spring 88 to engage the teeth 78 on the extension 76 of the support shaft 72. As shown by arrow 92 in Figure 7 When the knee bolster 16' is moved from the first position to the second position, the pawl 86 rotates the knee bolster 16' in a first direction, as shown by arrow 90. Once the knee bolster 16' is in the second position, the pawl 86 prevents the knee bolster 16' from rotating in a second direction, as shown by arrow 94, thereby preventing the knee bolster 16' from moving from the second position to the first position, as shown by arrow 96 in Figure 7

[0059] The pawl 86 within the knee bolster 16' engages the teeth 78 on the extension 76 of the support shaft 72 to prevent rotational movement of the knee bolster 16' from the second position to the first position relative to the support shaft 72. When a frontal impact or sudden deceleration occurs, the knee 22 of the passenger 20 exerts a force on the knee bolster 16' that will exert a torque on the extension 76 of the support shaft 72 that is absorbed by the torsion bar 74. The torsion bar 74 can be a hollow or solid rod. The torsional resistance of the torsion bar 74 is based on its yield stress. The torsional resistance should be great enough to prevent the passenger 20 within the vehicle seat 10 from sliding forward, but small enough to absorb enough energy to prevent injury to the passenger 20. It should be understood that this structure can be reversed, where the torsion bar 74 of the support shaft 72 is fixedly attached to the knee bolster 16' and the pawl 86 is attached to the vehicle seat 10 or an adjacent structure, without departing from the scope of the present disclosure.

[0060] In the exemplary embodiment, the knee bolster 16 is manually moved between the first position and the second position by the passenger 20 sitting within the vehicle seat 10. For example, again referring to Figure 1 As shown by arrow 46, when the passenger 20 sits within the vehicle seat 10, the passenger manually slides the knee bolster 16 from the first position to the second position. When the passenger 20 wants to exit the vehicle seat 10, the passenger 20 manually disengages the engagement with the locking mechanism 40 by the manual release 42 and slides the knee bolster 16 from the second position to the first position, as shown by arrow 44.

[0061] ​In another exemplary embodiment, the knee bolster assembly 12 also includes a first motor element 98 adapted to move the knee bolster 16 between the first position and the second position. The first motor element 98 is controlled by a controller 100 that is in communication with sensors 102 within the vehicle. The sensors 102 can include, but are not limited to, sensors within the vehicle seat 10 or elsewhere in the vehicle that detect the presence of an occupant, sensors on the knee bolster assembly that detect the proximity or contact of a leg, sensors on the vehicle seat 10 or knee bolster assembly 12 that detect whether an occupant is pinched when the seat is closed or opened, sensors that detect whether a seat belt is buckled, sensors within the vehicle that detect vehicle operating parameters such as speed, sensors within the vehicle adapted to predict braking, emergency situations, or actual collisions, and sensors within the vehicle that detect when a door is opened or when the vehicle is in drive mode.

[0062] The controller 100 is a non-generic electronic control device having a preprogrammed digital computer or processor, memory or non-transitory computer readable medium for storing data such as control logic, software applications, instructions, computer code, data, lookup tables, and transceivers or input / output ports. The computer readable medium includes any type of media accessible by a computer, such as read-only memory (ROM), random access memory (RAM), hard disk drives, compact discs (CDs), digital video discs (DVDs), or any other type of memory. The "non-transitory" computer readable medium does not include wired, wireless, optical, or other communication links transferring transitory electromagnetic signals or other signals. The non-transitory computer readable medium includes media that can be permanently stored with data, and media that can store and overwrite data, such as rewritable optical discs or erasable memory devices. The computer code includes any type of program code, including source code, object code, and executable code.

[0063] In response to at least one of a plurality of first predetermined conditions, the controller 100 automatically moves the knee bolster 16 from the first position to the second position. These conditions include, but are not limited to, activation by an occupant, detection of an occupant on the seat pan 14 of the vehicle seat 10, engagement of a restraining device such as the seat belt 26, detection that the vehicle seat 10 has been reclined beyond a predetermined angle, the vehicle exceeding a predetermined speed, an emergency brake is engaged, a collision is imminent is detected, or an impact is detected. For safety considerations in an autonomous vehicle, the occupant can be required to have the seat belt 26 buckled before the knee bolster 16 is automatically moved. In such an embodiment, the knee bolster 16 will only be automatically moved from the first position to the second position when engaged with the occupant restraint system for an occupant 20 seated in the vehicle seat 10. Further, the knee bolster 16 can stop and reverse movement if a pinching sensor detects a pinching of the occupant's body. The knee bolster 16 can also stop movement when a leg is contacted, as determined by a contact sensor, or when the knee bolster has moved a certain distance away from the leg, as determined by a proximity sensor.

[0064] In response to at least one of a plurality of second predetermined conditions, the knee bolster 16 will automatically move from the second position to the first position. These conditions can include, but are not limited to, deactivation by the occupant, release of a restraint device, such as the seat belt 26, detection that the vehicle seat 10 has been moved upward from the reclined position beyond a predetermined angle, the vehicle door being opened, the vehicle having exited its drive mode, or the vehicle engine being turned off.

[0065] In another exemplary embodiment, the first motorized element 98 is self-locking. For example, the first motorized element 98 can be a worm drive having a gear ratio that provides self-locking, the worm drive having a gear ratio that provides a high mechanical advantage, and depending on the helix angle of the gear, the output cannot back drive the input, thus, when the first motorized element 98 moves the knee bolster 16 to the second position, the knee bolster 16 is locked in the second position.

[0066] Referring to Figure 10 In another exemplary embodiment, the knee bolster 16" includes a first portion 16A movably mounted to a first side 104 of the vehicle seat 10 and a second portion 16B movably mounted to a second side 106 of the vehicle seat 10'. Each of the first and second portions 16A, 16B is movable between a first position, as shown by the shading in Figure 10 and a second position, as shown by the solid in Figure 10 where, when moved to the first position, the occupant 20 is able to ingress and egress the vehicle seat 10, and when moved to the second position, the first and second portions 16A, 16B are positioned directly in front of the seat surface 14' of the vehicle seat 10' such that the legs of the occupant 20 seated within the vehicle seat 10' are positioned between the seat surface 14' of the vehicle seat 10' and the first and second portions 16A, 16B of the knee bolster 16". Each of the first and second portions 16A, 16B of the knee bolster 16" rotates about a longitudinal axis 108, as shown by the arrows 110.

[0067] In various exemplary embodiments, Figure 10 Each of the first and second portions 16A, 16B of the knee bolster 16" can include the features described above, such as the locking mechanism 40 and the torsion bar 74 for absorbing energy. As shown, the second portion 16B of the knee bolster 16" includes the occupant's work surface 18' that is usable in both the first or second positions, and includes a cup holder. Referring to Figure 11 In an exemplary embodiment, each of the first and second portions 16A', 16B' of the knee bolster 16"' includes a first motorized element 98' adapted to automatically rotate the first and second portions 16A', 16B' of the knee bolster 16"' between the first and second positions as described above. As Figure 10 and Figure 11As shown, the first and second portions of the knee bolster 16'" rotate about a generally vertical axis between the first and second positions, as indicated by arrow 110. Referring to Figure 12 In another exemplary embodiment, the first and second portions 16A", 16B" of the knee bolster 16 rotate about a horizontal axis 112 between the first and second positions, as indicated by arrow 114.

[0068] Referring to Figure 13 In another exemplary embodiment, the first portion 16A" of the knee bolster 16"" includes a manual release 42 and an external indicium 70 adjacent the locking mechanism 40 adapted to indicate the position of the locking mechanism 40. Figure 12

[0069] Referring to Figure 14 In another exemplary embodiment, the knee bolster 216 is selectively horizontally movable relative to the seat pan 214 of the vehicle seat 210 when the knee bolster 216 is in the second position. As shown in the simplified schematic view of Fig. 18, the knee bolster 216 is supported on generally horizontal tracks 218 that allow the knee bolster 216 to move back and forth relative to the seat pan 214 of the vehicle seat 210, as indicated by arrow 220. In this manner, the knee bolster 216 can be adjusted to accommodate passengers of different sizes. A passenger seated in the vehicle seat 210 can also adjust the knee bolster 216 to vary the distance between the passenger's knees and the knee bolster 216. For example, if the passenger wants to sleep, it can be advantageous to move the knee bolster 216 very close to the passenger's knees to reduce the distance the passenger slides forward in the event of a hard braking crash. Alternatively, if the passenger wants more freedom of movement, the knee bolster 216 can be adjusted to increase the distance between the passenger's knees and the knee bolster. Figure 14

[0070] Referring to Figure 15 In another exemplary embodiment, the vehicle seat 310 includes a knee bolster assembly 312 that includes a second motor element 320 adapted to move the knee bolster 316 generally horizontally relative to the seat pan 314 of the vehicle seat 310. The vehicle seat 310 is shown to include the knee bolster 316 mounted on horizontal support tracks 318. The horizontal support tracks 318 include a first motor element 398 that engages a gear rack 322 within the knee bolster 316 to move the knee bolster 316 back and forth horizontally relative to the horizontal support tracks 318 between a first position and a second position.

[0071] ​​As indicated by arrow 326, the second motor element 320 is attached to the horizontal support rail 318 and moves the knee bolster 316 longitudinally forward and rearward relative to the seat pan 314 of the vehicle seat 310. The second motor element 320 can comprise any conventional mover, such as a servo motor or rotary motor that engages a threaded portion of the horizontal support rail 318. The second motor element 320 is controlled by the controller 100 in communication with the sensors 102 within the vehicle. In an exemplary embodiment, one of the sensors is used to detect the distance between the passenger's knee 22 and the knee bolster 316, and automatically moves the knee bolster 316 horizontally closer to the passenger's knee 22 and reduces the distance between the passenger's 20 knee 22 and the knee bolster 316 when other sensors within the vehicle detect an impending collision.

[0072] An energy absorbing device 332 is positioned on the horizontal support rail 318 to absorb energy when the passenger's 22 knee impacts the knee bolster 316. As shown, the energy absorbing device 332 is positioned between the second motor element 320 and the knee bolster 316 on the horizontal support rail 318, it should be understood that the energy absorbing device 332 can be connected to the support structure of the knee bolster 316 at other locations without departing from the scope of the present disclosure. The energy absorbing device 332 is adapted to cause the knee bolster 316 to move in a generally vertical, dampened motion when the passenger's 20 knee 22 within the vehicle seat 310 exerts a horizontal forward force on the knee bolster 316.

[0073] Referring to Figure 16 which is a schematic top view of a vehicle seat 310' in which the passenger 20 is seated, in an exemplary embodiment, the horizontal support rail 318' of the knee bolster 316' includes a support structure 334 within which the horizontal support rail 318' slides back and forth as indicated by arrow 336. The horizontal support rail 318' includes a knob 338 formed at a distal end thereof, and an energy absorbing material 340 positioned between the knob 338 and a support surface 342 of the support structure 334 and surrounding the horizontal support rail 318'. Figure 17 As indicated by arrow 344, forward movement of the knee bolster 316' compresses the energy absorbing material 340 positioned between the knob 338 and the support surface 342 of the support structure 334. As the energy absorbing material 340 is compressed, the impact energy of the passenger's 22 knee on the knee bolster 316' is absorbed. Figure 18 In another exemplary embodiment, the energy absorbing device 432 includes a horn-shaped knob 438 formed at a distal end of the horizontal support rail 418. As indicated by arrow 442, the horizontal support rail 418 is positioned within an extrudable material 440 such that forward movement of the knee bolster 316' causes expansion of the extrudable material 440 and absorption of energy.

[0074] The description of the present disclosure is merely exemplary in nature and variations that do not depart from the spirit and scope of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

Claims

1. A knee bolster assembly for a vehicle seat, comprising: a knee bolster movably mounted adjacent the vehicle seat, the knee bolster including a tray portion, the knee bolster and the tray portion having an L-shaped cross-section; the knee bolster being selectively movable between a first position and a second position, wherein in the first position the knee bolster and the tray portion are positioned to one side of a seat pan of the vehicle seat, and in the second position the knee bolster is positioned directly in front of the seat pan of the vehicle seat and the tray portion is positioned above the seat pan, wherein the tray portion provides a work surface for an occupant when the knee bolster is in the second position; wherein the knee bolster includes lateral tracks that slidably engage tracks on the vehicle seat to guide movement of the knee bolster relative to the vehicle seat in a lateral direction between the first position and the second position; the knee bolster being adapted to prevent an occupant in the vehicle seat from sliding forward out of the seat and to limit hyperextension of lower limbs due to forward inertia; and a locking mechanism adapted to secure the knee bolster in the second position, and at least one of a manual release and an automatic release adapted to selectively release the locking mechanism; an external marker adjacent the locking mechanism and adapted to indicate a position of the locking mechanism to guide a mechanic or first responder to the position of the locking mechanism, wherein the external marker identifies a cutting area to enable the locking mechanism to be severed to release the knee bolster in the event of damage to the manual release and automatic release; an energy absorbing device adapted to absorb energy when a knee or leg of an occupant in the vehicle seat impacts the knee bolster.

2. The knee bolster assembly of claim 1, wherein the knee bolster includes a rigid reaction plate and a cushion member that is attached to a surface of the rigid reaction plate facing the seat pan of the vehicle seat when the knee bolster is in the second position, and is made of a deformable material adapted to absorb energy when a knee of an occupant in the vehicle seat exerts a generally vertical force on the knee bolster.

3. The knee bolster assembly of claim 1, wherein the knee bolster is slidably movable between the first position and the second position.

4. The knee bolster assembly of claim 1, wherein the knee bolster is adapted to be manually moved between the first position and the second position by an occupant seated in the vehicle seat.

5. The knee pillow assembly of claim 1, further comprising a first motor element adapted to move the knee pillow between the first position and the second position, wherein, the knee bolster being adapted to automatically move from the first position to the second position in response to at least one of a first plurality of predetermined conditions, and to move from the second position to the first position in response to at least one of a second plurality of predetermined conditions.

6. The knee bolster assembly of claim 5, wherein the knee bolster is adapted to automatically move from the first position to the second position only when a passenger restraint system is provided for an occupant seated in the vehicle seat.

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