Modular carrier assembly for rotary mechanism

Abstract

A seat assembly for a motor vehicle has a seat base, a seat cushion, and a swivel mechanism. The swivel mechanism includes a lower plate fixedly coupled to the seat base by a structural attachment, an upper plate rotatably coupled to the lower plate, and a modular carrier assembly fixedly coupled to the upper plate and fixedly coupled to the seat cushion. The modular carrier assembly includes a tubular frame fixedly coupled to the upper plate. The tubular frame includes a front portion and a rear portion extending between a left portion and a right portion, where the tubular frame surrounds an opening extending vertically through the tubular frame to provide vertical access to a lower attachment aperture in the seat base.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 346,340, filed on May 27, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to a seat assembly for use in a motor vehicle. More particularly, the present invention relates to a modular carrier assembly for use in a motor vehicle seat assembly having a swivel mechanism configured to allow the seat assembly to rotate between a forward facing position and a rearward facing position. Background Art

[0004] A motor vehicle typically includes one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above the vehicle floor. It is known that some seat assemblies are capable of pivoting between a forward facing position and a rearward facing position. It is also known that some seat assemblies include a swivel mechanism that is operatively coupled between the seat cushion and a seat base (such as a riser bracket or a track assembly, as an example) and is configured to allow the seat cushion to rotate between a forward facing position and a rearward facing position. The swivel mechanism typically includes an upper plate rotatably coupled to a lower plate. Rollers and / or bearings are typically positioned between the upper plate and the lower plate to allow the swivel mechanism to rotate smoothly. In addition, the lower plate is typically fastened to the seat base by welding or by a plurality of mechanical fasteners extending through structural attachment holes in the lower plate.

[0005] Some seat assemblies include one or more large brackets that are attached to the upper plate and fixedly coupled to other components of the seat assembly such as the cushion frame, back frame, reclining mechanism, electric motor, control module, etc. Likewise, certain functional components such as latch mechanisms, electric motors, control modules, etc. may be fixedly coupled to the upper plate. Additionally, some swivel mechanisms may need to be modified to add or remove functional components from the swivel mechanism for use in high content seat assemblies and low content seat assemblies.

[0006] In addition, some seat assemblies include an upper stamping for seat integration. The upper stamping is fixedly coupled to the upper plate and the seat cushion. Some upper stampings have a generally C-shaped shape, wherein the rear portion extends between opposing side portions. The side portions and the rear portion surround a central opening and include a gap between distal ends of the side portions. The upper stamping is typically fixedly coupled to the upper plate with the gap facing forward.

[0007] Yet, known seat assembly may need to make the swivel mechanism rotate to provide the approach to the lower attachment hole in the seat base.In addition, different upper stampings may be needed to assemble the upper plate to various seat cushions.

[0008] Therefore, it is desirable to provide access to the lower attachment holes in the seat base when the seat assembly is facing forward. Additionally, it is desirable to improve the assembly of the swivel mechanism while providing a simplified environment to add, subtract, and change the functional components of the swivel mechanism for use in different seat assemblies. Furthermore, it is desirable that the swivel mechanism be customizable to mount to different seat cushions without requiring a customized upper stamping. Summary of the invention

[0009] According to one embodiment, a seat assembly for a motor vehicle is provided. The seat assembly includes a seat base, a seat cushion, and a swivel mechanism. The swivel mechanism includes a lower plate fixedly coupled to the seat base by a structural attachment, an upper plate rotatably coupled to the lower plate, and a modular carrier assembly fixedly coupled to the upper plate and fixedly coupled to the seat cushion. The modular carrier assembly includes a tubular frame fixedly coupled to the upper plate. The tubular frame includes a front portion and a rear portion extending between a left portion and a right portion, wherein the tubular frame surrounds an opening extending vertically through the tubular frame to provide vertical access to a lower attachment hole in the seat base.

[0010] According to another embodiment, a modular carrier assembly for use in a vehicle seat assembly having a swivel mechanism is provided. The modular carrier assembly includes a tubular frame including a front portion and a rear portion extending between a left portion and a right portion, wherein the tubular frame surrounds an opening extending vertically through the tubular frame. The modular carrier assembly also includes laterally spaced apart seat supports fixedly coupled to the left and right portions of the tubular frame, respectively, and a functional component fixedly coupled to the tubular frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Advantages of the present invention will be readily appreciated as they become better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0012] Figure 1 is a perspective view of a seat assembly according to one embodiment of the present invention, the seat assembly comprising a seat cushion, a seat base, and a swivel mechanism pivotally coupled between the seat cushion and the seat base, wherein the swivel mechanism comprises a modular carrier assembly;

[0013] Figure 2 According to one embodiment of the present invention Figure 1a top view of a swivel mechanism and a seat base, wherein the modular carrier assembly includes a swivel motor and a release actuator;

[0014] Figure 3 yes Figure 2 A perspective view of the rotating mechanism and the seat base;

[0015] Figure 4 According to one embodiment of the present invention Figure 3 A perspective view of a modular carrier assembly;

[0016] Figure 5 According to another embodiment of the present invention Figure 3 A perspective view of a rotation mechanism and a seat base, wherein the modular carrier assembly further includes a heater module and a seat control module; and

[0017] Figure 6 According to another embodiment of the present invention Figure 5 A three-dimensional view of a rotating mechanism and a seat base, wherein the modular carrier assembly includes a manual release assembly. DETAILED DESCRIPTION

[0018] Figures 1 to 6 Components of an automotive seat assembly 10 for use in a motor vehicle according to the embodiments described herein are illustrated. Directional references such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, etc., used or shown in the specification, drawings, or claims are relative terms used for ease of description and are not intended to limit the scope of the invention in any way. Referring to the drawings, like reference numerals indicate like or corresponding components throughout the several views.

[0019] exist Figure 1 , the seat assembly 10 includes a seat cushion 12, a seat back 14 pivotally coupled to the seat cushion 12, and a seat base 16 configured to support the seat assembly 10 above a vehicle floor 18. Without changing the scope of the present invention, the seat base 16 may include a pair of laterally spaced riser brackets 20 that are fixedly coupled directly to the vehicle floor 18 or fixedly coupled to other components of the seat base 16 such as a track assembly, a height adjustment mechanism, a tilt mechanism, etc. In addition, the seat assembly 10 includes a swivel mechanism 22 that pivotally couples the seat cushion 12 to the seat base 16. The swivel mechanism 22 allows the seat cushion 12 to selectively pivot relative to the seat base 16 between a forward facing position and a rearward facing position.

[0020] Reference Figure 2 and Figure 3, the swivel mechanism 22 includes a lower plate 24 fixedly coupled to the seat base 16 and configured to provide support for the swivel mechanism 22. The lower plate 24 includes a platform 26 extending between a left side portion 28 and a right side portion 30 and between a front side portion 32 and a rear side portion 34. The lower plate 24 also includes a rim 36 extending around the outer periphery of the platform 26. In addition, the lower plate 24 includes spaced-apart clearance holes 38 extending vertically through the platform 26 near the left side portion 28 and the right side portion 30 and configured to align with lower attachment holes 40 in the riser bracket 20. During assembly, structural attachments 42, such as mechanical fasteners, are inserted through holes (not shown) in the lower plate 24 and the riser bracket 20 to fixedly couple the lower plate 24 to the riser bracket 20. Alternatively, the riser bracket 20 may be welded to the lower plate 24 without changing the scope of the present invention. The rotating mechanism 22 also includes an upper plate 44 that is rotatably coupled to the lower plate 24 via rollers and / or bearings (not shown) positioned therebetween to allow the rotating mechanism 22 to rotate smoothly, as is known in the art.

[0021] The swivel mechanism 22 includes a modular carrier assembly 46 (hereinafter referred to as a "carrier assembly") that includes a tubular frame 48 configured to support the seat cushion 12. Figure 4 , the tubular frame 48 includes a front portion 50 longitudinally spaced apart from a rear portion 52. The tubular frame 48 also includes opposite left and right portions 54, 56 extending between the front and rear portions 50, 52. The tubular frame 48 includes an opening 58 extending vertically through the tubular frame and bounded by the left and right portions 54, 56 and the front and rear portions 50, 52. A pair of laterally spaced apart passages 60 extend vertically through the front and rear portions 50, 52 of the tubular frame 48. The carrier assembly 46 may include one or more of a bushing 62, a gasket 64, etc. assembled with each of the passages 60. The tubular frame 48 has a generally rectangular cross-sectional shape. However, it should be understood that the cross-sectional shape and overall shape of the tubular frame 48 may vary without changing the scope of the present invention. Referring to Figure 2 and Figure 3 , clearance holes 38 in lower plate 24 are vertically accessible through openings 58 in tubular frame 48 without requiring rotation of swivel mechanism 22 away from a forward facing position. Bearing assembly 46 with tubular frame 48 allows access to lower attachment holes 40 in riser support 20 through openings 58 in tubular frame 48 and through clearance holes 38 in lower plate 24.

[0022] exist Figure 4, the carrier assembly 46 also includes laterally spaced apart seat brackets 66 that are fixedly coupled to the respective left and right portions 54, 56 of the tubular frame 48 and are configured to be fixedly coupled to the seat cushion 12 or the seat back 14. It should be understood that the seat brackets 66 may be fixedly coupled to the rear portion 52 and / or the front portion 50 without changing the scope of the present invention. The seat brackets 66 include spaced apart mounting holes 68 that extend laterally through the seat brackets 66. Referring to Figure 1 , the seat assembly 10 includes mechanical fasteners (not shown) that are inserted through the mounting holes 68 and into the seat cushion 12 to fixedly couple the seat bracket 66 to the seat cushion 12. In addition, the carrier assembly 46 includes a cushion frame support bracket 70 that is fixedly coupled to the left and right portions 54, 56 of the tubular frame 48, respectively. The cushion frame support bracket 70 is configured to support a cushion frame (not shown) of the seat assembly 10.

[0023] exist Figure 3 and Figure 4 , the carrier assembly 46 may also include a welded reinforcement 72 that fixedly couples the ends of the tubular frame 48. The rotation mechanism 22 also includes bolts 74 that fixedly couple the tubular frame 48 to the upper plate 44. The bolts 74 are inserted through holes (not shown) in the upper plate 44, pass through corresponding passages 60 in the tubular frame 48, and are tightened with nuts 76.

[0024] Reference Figure 3 , the carrier assembly 46 may also include a support bracket 78 that is fixedly coupled to the tubular frame 48 and provides support for certain functional components. The support bracket 78 is a generally triangular-shaped bracket having a central section 80 extending between a rearward section 82 and a forward section 84. The rearward section 82 and the forward section 84 are fixedly coupled to the rear portion 52 and the front portion 50 of the tubular frame 48, respectively. The support bracket 78 is axially spaced between the tubular frame 48 and the nut 76, wherein the bolts 74 extend through holes (not shown) in the support bracket 78. It should be understood that the general shape of the support bracket 78, the number of bolts 74 attaching the support bracket 78 to the tubular frame 48, and the location of the passage 60 in the tubular frame 48 may vary without changing the scope of the present invention.

[0025] The rotation mechanism 22 also includes a latch mechanism 86 that is fixedly coupled to the upper plate 44 and configured to selectively prevent the upper plate 44 from rotating relative to the lower plate 24 when the latch mechanism 86 is in a latched state. When the latch mechanism 86 is in an unlatched state, the upper plate 44 can rotate relative to the lower plate 24. The carrier assembly 46 may also include a release actuator 88 that is operatively coupled to the latch mechanism 86 and configured to selectively unlatch the latch mechanism 86. The release actuator 88 includes a power connector 90 for attaching a wiring harness (not shown) configured to provide power to the release actuator 88. The release actuator 88 is fixedly coupled to the support bracket 78 by a mechanical fastener 92, wherein the release actuator 88 is supported within the opening 58 in the tubular frame 48.

[0026] Still Figure 3 As shown in the figure, the carrier assembly 46 can also include a rotary motor 94, which is operatively connected to the upper plate 44 and is configured to selectively rotate the upper plate 44 relative to the lower plate 24 when the latch mechanism 86 is in the unlatched state. The rotary motor 94 is fixedly connected to the support bracket 78 by a mechanical fastener 100, wherein the rotary motor 94 is supported in an opening 58 in the tubular frame 48. In addition, the rotary motor 94 includes a power connector 96, which is used to attach a wiring harness (not shown) configured to provide power to the rotary motor 94. The release actuator 88 and the rotary motor 94 are examples of functional components that can be incorporated into the carrier assembly 46. The opening 58 in the tubular frame 48 provides a wiring harness pass-through space 98 in the carrier assembly 46, thereby allowing one or more wiring harnesses (not shown) to be easily connected to the power connectors 90, 96 on the release actuator 88, the rotary motor 94, etc. The carrier assembly 46 has an open design that provides ease of connecting to electrical components and routing wiring harnesses through the carrier assembly 46 (not shown).

[0027] exist Figure 5 A second embodiment of a carrier assembly 46' is shown in FIG. 4, wherein like reference numerals denote similar elements to those described above. Figure 3 In addition to the rotary motor 94' and release actuator 88' shown in FIG. Figure 5The second embodiment shown in includes a heater module 102 and a seat control module 104. Only the significant differences between the two embodiments are reflected in the following figures and description. As is well known in the art, the heater module 102 and the seat control module 104 are electronic control modules (ECUs). The heater module 102 and the seat control module 104 are fixedly connected to the left portion 54' of the tubular frame 48' and are at least partially supported in the opening 58' in the tubular frame 48'. It will be understood that without changing the scope of the present invention, the functional components including the heater module 102 and the seat control module 104 as non-limiting examples can be fixedly connected to other locations on the tubular frame 48' and can include mounting brackets (not shown). In addition, it will be understood that without changing the scope of the present invention, the carrier assembly 46' can include other electronic control modules (ECUs).

[0028] exist Figure 6 A third embodiment of a carrier assembly 46" is shown in FIG. 4, wherein the same double quote reference numerals denote elements similar to those described above. Figure 6 The third embodiment shown in FIG. 1 depicts a method of replacing the Figure 3 86″. The manual release assembly 106 of the release actuator 88 is shown in the drawings. Only the significant differences between the various embodiments are reflected in the drawings and the following description. The manual release assembly 106 is configured to manually unlatch the latch mechanism 86″. The manual release assembly 106 includes a rod 108 having a proximal end operatively connected to the latch mechanism 86″ by a cable 110 and a distal end fixedly connected to a release handle 112. The manual release assembly 106 also includes a handle bracket 114, which is fixedly connected to the front portion 50″ of the tubular frame 48″ by spaced bolts 74″. In addition, the manual release assembly 106 includes a track 116, which is fixedly connected to the handle bracket 114 and includes a channel 118 extending longitudinally along the track 116. The rod 108 is slidably connected to the channel 118 and travels within the handle bracket 114 during actuation of the manual release assembly 106.

[0029] As discussed above, the seat assembly 10 of the present invention includes a swivel mechanism 22 that includes a modular carrier assembly 46, 46', 46". fixedly coupled to an upper plate 44. The modular carrier assembly 46, 46', 46" includes a tubular frame 48, 48', 48", having openings 58, 58', 58" extending through the tubular frame 48, 48', 48", and providing mounting surfaces for functional components such as a release actuator 88, 88', a swivel motor 94, 94', a heater module 102, a seat control module 104, a manual release assembly 106, a seat bracket 66, a cushion frame support bracket 70, and the like. In addition, the openings 58, 58', 58" in the tubular frames 48, 48', 48" provide vertical access to the lower attachment hole 40 in the riser bracket 20 and the clearance hole 38 in the lower plate 24 without requiring rotation of the swivel mechanism 22. The modular carrier assemblies 46, 46', 46" provide a simplified environment to add, subtract and change functional content from the rotating mechanism 22 for use in high content seat assemblies and low content seat assemblies 10. In addition, the modular carrier assemblies 46, 46', 46" allow for easy addition, removal and replacement of various mounting brackets, such as the support bracket 78 and the seat bracket 66.

[0030] The present invention has been described in an illustrative manner, and it should be understood that the terms used are intended to be in the nature of descriptive terms rather than restrictive terms. In light of the above teachings, many modifications and variations of the present invention are possible. Therefore, it should be understood that within the scope of the appended claims, the present invention may be practiced in a manner other than that specifically described.

Claims

1. A seat assembly for a motor vehicle, the seat assembly comprising: a seat base having a lower attachment hole; Seat cushions; as well as a swivel mechanism including a lower plate fixedly coupled to the seat base by a structural attachment, an upper plate rotatably coupled to the lower plate, and a modular carrier assembly fixedly coupled to the upper plate and fixedly coupled to the seat cushion, wherein the modular carrier assembly includes a tubular frame fixedly connected to the upper plate, the tubular frame including a front portion and a rear portion extending between a left portion and a right portion, wherein the tubular frame surrounds an opening extending vertically through the tubular frame to provide vertical access to the lower attachment hole.

2. The seat assembly of claim 1, wherein: The modular carrier assembly also includes laterally spaced apart seat supports fixedly coupled to the tubular frame and fixedly coupled to the seat cushion.

3. The seat assembly of claim 2, wherein: The rotation mechanism also includes a latch mechanism operatively coupled to the upper plate and configured to selectively prevent the upper plate from rotating relative to the lower plate.

4. The seat assembly of claim 3, wherein: The modular carrier assembly further includes a manual release assembly including a handle bracket fixedly coupled to the tubular frame and a release handle slidably coupled to the handle bracket and operatively coupled to the latch mechanism; and A manual release assembly is configured to selectively unlatch the latch mechanism, thereby allowing the upper plate to rotate relative to the lower plate.

5. The seat assembly of claim 3, wherein: The modular carrier assembly further includes a support bracket fixedly coupled to the tubular frame and a release actuator fixedly coupled to the support bracket and operatively coupled to the latch mechanism; and The release actuator is configured to selectively unlatch the latch mechanism, thereby allowing the rotation mechanism to rotate.

6. The seat assembly of claim 5, wherein: The modular carrier assembly further includes a rotary motor fixedly coupled to the support bracket and operatively coupled to the upper plate; and The rotary motor is configured to selectively rotate the upper plate relative to the lower plate.

7. The seat assembly of claim 6, wherein: The rotary motor and the release actuator are supported by the support bracket and are at least partially positioned within the opening in the tubular frame.

8. The seat assembly of claim 7, wherein: The modular carrier assembly also includes a wiring harness pass-through space within the opening in the tubular frame that provides access to power connectors on the rotary motor and the release actuator.

9. The seat assembly of claim 8, wherein: The modular carrier assembly also includes a heater module fixedly coupled to the tubular frame.

10. The seat assembly of claim 8, wherein: The modular carrier assembly also includes a seat control module fixedly coupled to the tubular frame.

11. The seat assembly of claim 2, wherein: The lower attachment aperture is accessible through a clearance aperture in the lower plate and the opening in the tubular frame when the swivel mechanism is in a forward facing position.

12. A modular carrier assembly for use in a vehicle seat assembly having a swivel mechanism, the modular carrier assembly comprising: a tubular frame including a front portion and a rear portion extending between the left portion and the right portion, wherein the tubular frame surrounds an opening extending vertically through the tubular frame; laterally spaced apart seat supports fixedly coupled to the left and right portions of the tubular frame, respectively; and A functional component is fixedly coupled to the tubular frame.

13. The modular carrier assembly of claim 12, wherein: The functional component includes a manual release assembly fixedly coupled to the tubular frame.

14. The modular carrier assembly of claim 12, wherein: The functional component includes an electronic control module fixedly coupled to the tubular frame.

15. The modular carrier assembly of claim 14, wherein: The electronic control module includes a heater module.

16. The modular carrier assembly of claim 14, wherein: The electronic control module includes a seat control module.

17. The modular carrier assembly of claim 12, further comprising: A support bracket is fixedly coupled to the front portion and the rear portion of the tubular frame.

18. The modular carrier assembly of claim 17, wherein: The functional component includes a release actuator fixedly coupled to the support bracket and positioned at least partially within the opening in the tubular frame.

19. The modular carrier assembly of claim 18, wherein: The functional component also includes a rotary motor fixedly coupled to the support bracket and positioned at least partially within the opening in the tubular frame.

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