Modular rotary damper for high torque applications

Abstract

A rotary damper for an automobile seat assembly, the rotary damper comprising: an inner cover (30); a pivot pin (54) that is fixedly coupled to the inner side cover; an actuation bracket (106), which is coupled to the pivot pin (54) in a pivotable manner and comprises an actuation projection (112); a leaf spring (182) fixedly coupled to the inner side cover (30); and a damper roller (122) coupled to the actuation bracket (106) and configured to frictionally engage with the leaf spring (182) when the actuation bracket is rotated in the forward rotational direction. The rotary damper also includes an outer cover (154) pivotably coupled to the pivot pin (54) and fixedly coupled to the actuation projection (106). When the outer cover (154) is rotated in a forward rotational direction with respect to the inner cover (30), the rotational damper dampens a rotational speed of the outer cover (154) when the damper roller (122) is frictionally engaged with the leaf spring (182), and the rotational speed is not damped when the damper roller (122) is disconnected from the leaf spring (182).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 409,296, filed on September 23, 2022, the entire disclosure of which is hereby incorporated by reference. Technical Field

[0003] The present invention relates to seat assemblies for use in automotive vehicles. More particularly, the present invention relates to modular rotary dampers for use in automotive seat assemblies. 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 generally known that the seat back is capable of pivoting between a reclined position, an upright position, and a folded flat position in which the seat back covers the seat cushion. It is generally known that the seat assembly includes a disc recliner configured to lock the seat back into one or more inclined positions. A release handle is provided to unlock the disc recliner when the release handle is actuated. In addition, it is generally known that the seat assembly includes a seat back return spring configured to bias the seat back toward the upright position and optionally toward the folded flat position.

[0005] To adjust the seat back from the reclined position to the upright position, the occupant actuates the release handle, thereby unlocking the disc recliner. After the disc recliner is unlocked, the seat back return spring automatically moves the seat back to the upright position. Once the seat back is adjusted, the occupant releases the release handle, and the disc recliner is relocked. To reconfigure the seat assembly for cargo carrying, the occupant actuates the release handle while standing outside the vehicle to unlock the disc recliner. Next, the return spring or the occupant pivots the seat back from the upright position toward the folded flat position.

[0006] Some rear seat assemblies include a split seat back that includes a 60% seat back and a 40% seat back. Due to the weight of the 60% seat back, the force or torque required to reposition the 60% seat back from the reclined position to the upright position is relatively large. Therefore, the rear seat assembly typically includes a strong seat back return spring attached to the 60% seat back. However, the strong seat back return spring and / or the weight of the seat back may result in excessive seat back velocity when pivoting the seat back from the upright position to the folded flat position.

[0007] It is desirable that the seat assembly include a damper configured to reduce the velocity of the seat back as the seat back rotates from the upright position toward the fold-flat position. Summary of the invention

[0008] According to one embodiment, a rotary damper for a car seat assembly is provided. The rotary damper includes: an inner cover; a pivot pin fixedly connected to the inner cover; an actuating bracket pivotally connected to the pivot pin and including an actuating protrusion; and a leaf spring having a head end fixedly connected to the inner cover and a free end spaced apart from the head end. In addition, the rotary damper includes a damper roller connected to the actuating bracket and configured to selectively engage with the leaf spring when the actuating bracket rotates in a forward rotation direction and selectively disengage from the leaf spring when the actuating bracket rotates in a backward rotation direction opposite to the forward rotation direction. The rotary damper also includes an outer cover pivotally connected to the pivot pin and fixedly connected to the actuating protrusion so that the outer cover and the actuating bracket rotate together. When the outer cover rotates in a forward rotational direction relative to the inner cover, the rotational damper damps a rotational speed of the outer cover when the damper roller engages with the leaf spring, and the rotational speed is not damped when the damper roller is disengaged from the leaf spring.

[0009] According to another embodiment, a seat assembly for use in a motor vehicle is provided. The seat assembly includes: a seat cushion; a seat back pivotally connected to the seat cushion and capable of pivoting between a first seat back position and a second seat back position; and a rotary damper operatively connected between the seat back and the seat cushion. The rotary damper includes: an inner cover fixedly connected to the seat cushion; a pivot pin fixedly connected to the inner cover; and an actuating bracket pivotally connected to the pivot pin and including an actuating protrusion. The rotary damper also includes a leaf spring having a head end fixedly connected to the inner cover and a free end spaced apart from the head end. In addition, the rotary damper includes a damper roller connected to the actuating bracket and configured to selectively engage with the leaf spring when the actuating bracket rotates in a forward rotational direction. In addition, the rotary damper further includes an outer side cover fixedly coupled to the seat back, pivotally coupled to the pivot pin, and fixedly coupled to the actuating protrusion so that the outer side cover and the actuating bracket rotate together. When the seat back rotates in the forward rotation direction, the rotary damper damps the rotation speed of the seat back when the damper roller is engaged with the leaf spring, and the rotation speed is not damped when the damper roller is disengaged from the leaf spring. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0011] Figure 1is a perspective view of a seat assembly according to one embodiment of the present invention, the seat assembly including a seat cushion, a seat back and a rotary damper;

[0012] Figure 2 yes Figure 1 an enlarged view of part 2;

[0013] Figure 3 yes Figure 2 A left rear perspective view of a rotary damper;

[0014] Figure 4 yes Figure 3 A right front perspective view of a rotary damper;

[0015] Figure 5 yes Figure 4 A left side view of the rotary damper, wherein the rotary damper is in a backward state;

[0016] Figure 6 yes Figure 5 An exploded view of a rotary damper of the type shown in FIG. 1 , the rotary damper comprising a pivot pin and a leaf spring;

[0017] Figure 7 yes Figure 6 A perspective view of a pivot pin;

[0018] Figure 8 yes Figure 6 A three-dimensional diagram of a leaf spring;

[0019] Fig. 9 yes Figure 5 a left side view of a rotary damper of the invention, wherein the rotary damper is in a rearward position and the outer side cover is removed;

[0020] Fig.10 It is along Figure 5 The section 10-10 in Figure 5 A cross-sectional view of a rotary damper;

[0021] Fig.11 It is along Figure 5 The section 11-11 in Figure 5 A cross-sectional view of a rotary damper;

[0022] Fig.12 is a schematic diagram of a seat assembly according to one embodiment of the present invention, illustrating a reclined position, an upright position, and a folded flat position of a seat back;

[0023] Fig.13 yes Figure 5 A left side view of the rotary damper, wherein the rotary damper is in an upright state;

[0024] Fig.14yes Fig.13 a left side view of a rotary damper of , wherein the rotary damper is in an upright position and the outer side cover is removed;

[0025] Fig.15 yes Fig.14 An enlarged perspective view of a portion 15 of the rotary damper, wherein the rotary damper is in a damping state;

[0026] Fig.16 yes Fig.13 A left side view of the rotary damper, wherein the rotary damper is in a forward state;

[0027] Fig.17 yes Fig.16 A left side view of the rotary damper of FIG. 1 , wherein the rotary damper is in a forward position and the outer side cover is removed;

[0028] Fig.18 is a left side view of a rotary damper according to another embodiment of the present invention; and

[0029] Fig.19 yes Fig.18 Left side view of the rotary damper with the outer side cover removed. DETAILED DESCRIPTION

[0030] Figures 1 to 19 Components of a rotary damper 10 for use in a seat assembly 12 of a motor vehicle are illustrated according to the embodiments described herein. Directional references such as top, bottom, upper, lower, upward, downward, longitudinal, lateral, left, right, etc., used or shown in the specification, drawings, or claims are relative terms used for convenience of description and are not intended to limit the scope of the present invention in any aspect. Referring to the drawings, like reference numerals indicate like or corresponding parts throughout the several views.

[0031] like Figure 1 As depicted in , the seat assembly 12 includes a seat cushion 14 and a seat back 16 that is pivotally coupled to the seat cushion 14 via laterally spaced pivots 18, 20. The seat cushion 14 and seat back 16 are shown with the cushions and covers removed for illustrative purposes. The seat cushion 14 includes laterally spaced cushion brackets 22, 24. Additionally, the seat back 16 includes laterally spaced side brackets 25, 26. The pivots 18, 20 pivotally couple the side brackets 25, 26 to the respective cushion brackets 22, 24. As shown in FIG. Fig.12 As shown in FIG. 1 , the seat back 16 is pivotable between a reclined position 27, an upright position 28, and a folded flat position 29 covering the seat cushion 14. Figure 1 It is shown in the upright position 28 .

[0032] like Figure 1 and Figure 2 , the seat assembly 12 further includes a rotary damper 10 operatively coupled between the side bracket 25 and the cushion bracket 22. The rotary damper 10 is configured to selectively damp the rotational velocity of the seat back 16 when the seat back 16 rotates from the upright position 28 toward the folded flat position 29. In addition, the rotary damper 10 is configured to spring bias the seat back 16 toward the upright position 28 when the seat back 16 is in the reclined position 27. The seat assembly 12 optionally includes a second rotary damper 10 operatively coupled between the other side bracket 26 and the other cushion bracket 24. In addition, it will be understood that the rotary damper 10 may be operatively coupled between different first and second components of the seat assembly 12 without changing the scope of the present invention.

[0033] Reference Figures 2 to 11 , the rotary damper 10 includes an inner cover 30 having a substantially cylindrical shape. Figure 6 , the inner cover 30 includes a cylindrical wall 32 that projects laterally away from the inner side wall 34 and defines an internal cavity 36. The inner side wall 34 includes a D-shaped hole 38 extending laterally through the inner side wall 34. The cylindrical wall 32 includes a radially spaced inner cylindrical surface 32A and an outer cylindrical surface 32B that extend around the outer periphery of the inner side wall 34 and terminate at a lip 32C. In addition, the cylindrical wall 32 includes a groove 40 extending in a circumferential direction between opposite groove ends 42, 44 and between opposite groove sides 46, 48. In addition, the groove 40 extends through the cylindrical wall 32 and abuts the internal cavity 36. The cylindrical wall 32 also includes circumferentially spaced mounting holes 50, 52 that extend radially through the cylindrical wall 32 and are spaced from the groove 40.

[0034] like Figure 6 , Figure 7 , Fig.10 and Fig.11As shown in FIG. 1 , the rotary damper 10 further includes a pivot pin 54 having a generally cylindrical shape and extending between opposite inner and outer ends 56 and 58. The pivot pin 54 includes a pivot boss 60 having a generally cylindrical shape extending laterally inwardly from the outer end 58 and terminating at a boss end 62. In addition, the pivot boss 60 includes an outer pivot surface 64 extending circumferentially around the pivot boss 60, the outer pivot surface 64 defining an axis of rotation 66. The pivot pin 54 further includes a spring spindle 68 extending axially away from the boss end 62. The spring spindle 68 is a generally D-shaped cylindrical member having a curved surface 70 extending in a circumferential direction and abutting a flat surface 72 to form a D-shape in cross section. The curved surface 70 and the flat surface 72 extend axially between the opposite outer and inner ends 74 and 76. The spring spindle 68 abuts the pivot boss 60 such that a portion of the outboard end 74 projects radially away from the pivot surface 64, thereby forming an outboard protrusion that extends circumferentially along a portion of the pivot surface 64. Additionally, the flat surface 72 abuts the boss end 62 such that a portion of the boss end 62 extends radially away from the flat surface 72, thereby forming a boss protrusion.

[0035] The pivot pin 54 also includes a D-shaped boss 78 extending axially away from the inner end 76 of the spring spindle 68. The D-shaped boss 78 includes a curved surface 80 extending in a circumferential direction and abutting a flat surface 82 to form a D-shaped shape in cross section. The curved surface 80 and the flat surface 82 extend axially between the inner end 76 of the spring spindle 68 and the flange 84. The curved surface 70 of the spring spindle 68 is radially offset relative to the curved surface 80 of the D-shaped boss 78, so that a portion of the inner end 76 forms an inner protrusion extending circumferentially along at least a portion of the curved surface 80 of the D-shaped boss 78. In addition, the flat surface 82 is generally radially aligned with the flat surface 72 of the spring spindle 68. However, it will be understood that the flat surfaces 72, 82 can be radially offset from each other and / or non-parallel to each other. The flange 84 extends circumferentially along at least a portion of the curved surface 80, thereby defining a channel 86 between the flange 84 and the inner end 76. It will be appreciated that the flange 84 may be formed after the pivot pin 54 is assembled with the inboard cover 30 .

[0036] like Fig.10 and Fig.11, the D-shaped boss 78 may include a D-shaped end 56A sized and shaped to at least partially pass through the D-shaped hole 38 in the inner cover 30. During assembly, the D-shaped end 56A of the pivot pin 54 is inserted into the interior cavity 36 in the inner cover 30 and at least partially passes through the D-shaped hole 38. Next, the D-shaped end 56A of the pivot pin 54 may be riveted or staked to form a flange 84 and fixedly couple the inner cover 30 to the pivot pin 54. The D-shaped end 56A of the pivot pin 54, in combination with the D-shaped hole 38 in the inner cover 30, prevents relative rotation between the pivot pin 54 and the inner cover 30.

[0037] like Figure 6 As depicted in , the rotary damper 10 also includes a first inner spacer 94 and a second inner spacer 96 and an outer spacer 98. The spacers 94, 96, 98 are generally annular and have respective passages 100, 102, 104 extending axially through the spacers 94, 96, 98. Fig.10 and Fig.11 As shown in FIG. 8 , the spacers 94 , 96 , 98 are assembled on the pivot pin 54 , spaced apart along the spring spindle 68 , wherein the pivot pin 54 extends axially through passages 100 , 102 , 104 in the spacers 94 , 96 , 98 .

[0038] like Figure 6 As shown in , the rotary damper 10 also includes an actuation bracket 106, which includes a main disc 108 and an actuation protrusion 112, the main disc 108 having a central hole 110 extending axially through the main disc 108, and the actuation protrusion 112 protruding axially from the main disc 108. The actuation protrusion 112 includes an engagement surface 114 extending generally in the axial direction and terminating at a distal end wall 118 and an opposite side surface 116. Fig. 9 As shown in FIG. 1 , the actuation protrusion 112 includes a distal end surface 119 extending circumferentially between the engagement surface 114 and the side surface 116. Figure 6 The actuator bracket 106 further includes a roller hole 120 extending axially through the main disc 108 and radially offset relative to the central hole 110. Figures 9 to 11 , the actuation bracket 106 is sized and shaped to fit within the interior cavity 36 of the inner cover 30, wherein a portion of the actuation protrusion 112 optionally extends axially outside the interior cavity 36. When assembled as part of the rotary damper 10, the actuation bracket 106 is spaced between the first inner spacer 94 and the second inner spacer 96, wherein the pivot pin 54 extends through the central hole 110 in the actuation bracket 106 and the first inner spacer 94 is positioned between the inner side wall 34 of the inner cover 30 and the actuation bracket 106. In addition, the actuation bracket 106 is assembled on the pivot pin 54, wherein the actuation protrusion 112 is oriented away from the inner side wall 34 of the inner cover 30.

[0039] Also like Figure 6 As depicted in , the rotary damper 10 includes a damper roller 122. The damper roller 122 includes a roller 124 having a generally cylindrical shape. In addition, the damper roller 122 includes a roller pin 126 extending axially through the roller 124 and having an inner end 128 and an outer end 130. It will be understood that the roller 124 can be integrally formed with, rotationally coupled to, or fixedly coupled to the roller pin 126 without changing the scope of the present invention. Referring to Fig.10 The damper roller 122 is assembled with the actuation bracket 106 by inserting the inner end 128 of the roller pin 126 into the roller hole 120 in the actuation bracket 106 .

[0040] like Figure 6 , Fig. 9 and Fig.15 As shown in , the rotary damper 10 also includes a spring stopper 132 having a generally arcuate shape extending between a front surface 134 and a rear surface 136. In addition, the spring stopper 132 includes radially spaced inner and outer walls 138 and 140 sized and shaped to allow the outer wall 140 to be fixedly coupled to the inner cylindrical surface 32A of the inner cover 30. After assembly with the inner cover 30, the inner wall 138 of the spring stopper 132 is radially spaced from the outer side of the distal end surface 119 of the actuation protrusion 112. The spring stopper 132 is positioned on the inner cylindrical surface 32A of the inner cover 30 so that there is an axial gap between the spring stopper 132 and the main disc 108 of the actuation bracket 106. It will be understood that the spring stopper 132 can be formed integrally with the inner cover 30 without changing the scope of the present invention.

[0041] like Figure 6 , Fig. 9 and Fig.15 As depicted in , the rotary damper 10 also includes a clock spring 142, alternatively described as a helical torsion spring. The clock spring 142 is configured to spring bias the seat back 16 from the reclined position 27 toward the upright position 28. The spring stop 132 prevents the clock spring 142 from spring biasing the seat back 16 toward the folded flat position 29 when the rotary damper 10 dampens forward rotation of the seat back 16, as further described below. The clock spring 142 includes an inner end 144 that is configured to frictionally engage with or fixedly couple to a flat surface 72 on the spring spindle 68 on the pivot pin 54. The clock spring 142 also includes a protrusion 146 that extends radially inward from the outer end 148 and has a forward surface 150 opposite a rearward surface 152. As shown Fig. 9As shown in FIG. 1 , the forward surface 150 is configured to frictionally engage the engagement surface 114 on the actuation protrusion 112. Fig.15 The forward surface 150 is also configured to frictionally engage the front surface 134 of the spring stop 132. During assembly of the rotary damper 10, the clock spring 142 is assembled on the pivot pin 54 and axially spaced between the second inner spacer 96 and the outer spacer 98, as shown in FIG. Fig.10 As shown in .

[0042] like Figure 5 , Figure 6 and Fig.11 As depicted in , the rotary damper 10 also includes an outer cover 154 configured to be pivotally coupled to the pivot pin 54 and the inner cover 30. The outer cover 154 is generally disc-shaped, wherein an outer rim 156 extends radially outward from and circumferentially around the disc-shaped central portion 158. The outer rim 156 is configured to cooperatively and rotationally engage with the lip 32C on the inner cover 30 when the outer cover 154 is assembled with the inner cover 30, as shown in FIG. Fig.11 It will be appreciated that the outer rim 156 may be axially spaced from the cylindrical wall 32 on the inner cover 30 without changing the scope of the present invention.

[0043] Reference Figure 6 , the outer cover 154 also includes a pivot hole 160, a pin hole 162 and a bracket slot 164 that are spaced apart and extend axially through the central portion 158. Fig.10 As shown in , the pivot hole 160 is sized and shaped to rotationally couple with the pivot boss 60 on the pivot pin 54 after the pivot pin 54 is assembled with the inner cover 30 and the outer cover 154 is assembled with the inner cover 30. In addition, the pin hole 162 is sized and shaped to matingly engage with the outer end 130 of the roller pin 126 when the outer cover 154 is assembled with the inner cover 30 after the damper roller 122 is assembled with the actuation bracket 106. Figure 6 The bracket groove 164 is an arcuate groove having radially spaced inner and outer walls 166 and 168 extending between opposite first and second ends 170 and 172. The bracket groove 164 is sized and shaped to cooperatively engage with the actuation protrusion 112 when the outer cover 154 is assembled with the inner cover 30, wherein the distal wall 118 is at least partially inserted through the bracket groove 164, as shown in FIG. Figure 5 and Fig.10 As shown in .

[0044] like Figure 4 and Figure 6, the outer side cover 154 also includes an attachment flange 174 that projects generally radially outward from the outer edge 156. The attachment flange 174 includes spaced apart attachment holes 176, 178 that extend axially through the attachment flange 174. During assembly of the rotary damper 10 with the seat assembly 12, bolts (not shown) are inserted through the respective attachment holes 176, 178 and fixedly coupled to the side bracket 25 of the seat back 16.

[0045] Reference Figure 6 , Figure 8 and Fig. 9 , the rotary damper 10 further includes a leaf spring 182. Figure 8 and Fig. 9 As depicted in FIG. 1 , the leaf spring 182 is a bent leaf spring configured to engage with the damper roller 122 and provide damping when the damper roller 122 moves along the leaf spring 182. Figure 8 The leaf spring 182 includes a base portion 184 extending from a head end 186 and having a generally arcuate shape, the base portion 184 having an inner surface 188 configured to cooperatively engage with the outer cylindrical surface 32B of the inner cover 30, as shown in FIG. Fig. 9 In addition, the base portion 184 includes spaced rivet holes 190, 192 extending therethrough and configured to align with the mounting holes 50, 52 on the inner cover 30, respectively. Figure 6 , Fig. 9 and Fig.11 The rotary damper 10 further includes rivets 194 , 196 inserted through the respective rivet holes 190 , 192 and the respective mounting holes 50 , 52 to fixedly couple the base portion 184 of the leaf spring 182 to the inner cover 30 .

[0046] like Figure 8 and Fig. 9 As shown in , the leaf spring 182 also includes a bent portion 198 extending from the base portion 184 and adjacent to a curved portion 200, which terminates at a free end 202. The curved portion 200 includes a roller engagement area 204 extending along an inner surface 206 of the curved portion 200 between an upper end 208 and a lower end 210. In addition, the curved portion 200 includes a minimum damping position 212 located near the upper end 208 of the roller engagement area 204 and a maximum damping position 214 located near the lower end 210 of the roller engagement area 204. It will be understood that the leaf spring 182 can have any profile and / or geometry that will allow for the desired damping force when activated by the damper roller 122. As shown in FIG. Fig. 9As depicted in , the leaf spring 182 is sized and shaped so that the curved portion 200 can be inserted through the slot 40 in the cylindrical wall 32 of the inner cover 30 before the leaf spring 182 is fixedly coupled to the inner cover 30 by rivets 194, 196. When assembled, the leaf spring 182 extends through the slot 40 between the opposing slot ends 42, 44 and extends into the interior cavity 36 in the inner cover 30. The slot 40 and leaf spring 182 are sized and shaped so that the slot 40 provides a gap that allows the leaf spring 182 to flex as the damper roller 122 travels along the roller engagement area 204. As shown in FIG. Fig.11 As shown in FIG. 1 , the leaf spring 182 is axially positioned between the main disk 108 of the actuation bracket 106 and the outboard cover 154 and is generally axially aligned with the clock spring 142 .

[0047] like Figure 2 , Figure 4 and Figure 6 As depicted in , the rotary damper 10 also includes a lower bracket 216 configured to be fixedly coupled to the seat cushion bracket 22. Figure 4 and Figure 6 , the lower bracket 216 includes an arcuate flange 218 having an inner surface 220 configured to cooperatively engage the outer cylindrical surface 32B of the inner cover 30. During assembly, the inner surface 220 of the arcuate flange 218 is fixedly coupled to the outer cylindrical surface 32B. The lower bracket 216 also includes a base flange 222 that extends from the arcuate flange 218 at a substantially right angle and includes spaced apart holes 224, 226 extending through the base flange 222. Figure 2 As depicted in , the inner cover 30 is fixedly coupled to the cushion bracket 22 by bolts 228 , 230 that are inserted into corresponding holes 224 , 226 in the base flange 222 and fixedly coupled to holes (not shown) in the cushion bracket 22 .

[0048] Reference Fig.12 The seat back 16 of the seat assembly 12 can be repositioned between a reclined position 27, an upright position 28, and a folded flat position 29 according to the needs of the occupant by pivoting the seat back 16 about the pivots 18, 20. Figure 2 , the rotary damper 10 is operatively coupled to the seat assembly 12 via the attachment flange 174 on the outboard cover 154 that is fixedly coupled to the side bracket 25 and via the base flange 222 on the lower bracket 216 that is fixedly coupled to the cushion bracket 22. Although not shown in the drawings, the seat assembly 12 includes a locking mechanism, such as a disc recliner, configured to lock the seat back 16 into a selected rotational position, as is generally known in the art. The occupant selectively unlocks the locking mechanism (not shown) to allow the position of the seat back 16 to be adjusted.

[0049] Rotary damper 10 Figure 5 and Fig. 9 2 is shown in the rearward state, which corresponds to the seat back 16 being in the reclined position 27 ( Fig.12 ).like Figure 2 As depicted in , the pivot pin 54 is keyed to the D-shaped hole 38 in the inner cover 30, which in turn is fixedly coupled to the seat cushion bracket 22 via the lower bracket 216. Thus, the pivot pin 54 does not rotate relative to the lower bracket 216 and the seat cushion bracket 22. Fig. 9 , the spring stopper 132 is fixedly coupled to the inner cover 30 so that the front surface 134 on the spring stopper 132 does not rotate relative to the lower bracket 216. When the base portion 184 of the leaf spring 182 is fixedly coupled to the inner cover 30, the free end 202 of the leaf spring 182 can flex and change position relative to the lower bracket 216. In addition, the outer cover 154 is pivotally coupled to the pivot pin 54 and fixedly coupled to the actuation protrusion 112, as shown in FIG. Fig.10 As described in . Fig. 9 It will be appreciated that the rearward surface 152 of the clock spring projection 146 may be frictionally engaged or circumferentially spaced from the free end 202 of the leaf spring 182 when the rotary damper 10 is in the rearward state without altering the scope of the present invention.

[0050] When the rotary damper 10 is in the rearward position and the seat back 16 is in the locked position, the damper roller 122 is circumferentially spaced from the roller engagement area 204 on the leaf spring 182, as shown in FIG. Fig. 9 Thus, the leaf spring 182 does not apply a damping force to the damper roller 122. Additionally, the protrusion 146 of the clock spring 142 frictionally engages the engagement surface 114 on the actuation protrusion 112 and is circumferentially spaced from the front surface 134 on the spring stop 132. Fig. 9 As seen in FIG. 1 , when the clock spring protrusion 146 frictionally engages the actuation protrusion 112, the clock spring 142 applies a clockwise spring force (arrow 232) and spring biases the actuation bracket 106 in a clockwise direction (arrow 233). Figure 1 , Figure 5 , Fig. 9 and Fig.12 The clockwise spring force (arrow 232) applied by the clock spring 142 to the actuating protrusion 112 causes the outer cover 154 to be spring biased in the clockwise direction (arrow 233), which causes the seat back 16 to rotate in the forward direction 234 ( Figure 1 and Fig.12) spring biased because the actuation protrusion 112 is fixedly coupled to the bracket slot 164 in the outer side cover 154 and the attachment flange 174 is fixedly coupled to the side bracket 25. However, when the seat back 16 is in the locked state, the locking mechanism (not shown) prevents the seat back 16 from being repositioned by the rotary damper 10.

[0051] When the seat back 16 is in the reclined position 27 ( Fig.12 ), wherein the seat back 16 is in the locked state and the rotary damper 10 is in the rearward state ( Figure 5 and Fig. 9 ), the occupant initiates the return to upright process by unlocking the seat back 16. After the seat back 16 is unlocked, the clockwise spring force (arrow 232) applied by the clock spring 142 to the actuation protrusion 112 in the rotary damper 10 causes the actuation bracket 106 to rotate in a clockwise direction (arrow 233), which in turn causes the seat back 16 to pivot forward toward the upright position 28 (arrow 234), as shown in FIG. Fig.12 As the seat back 16 rotates forward from the reclined position 27 toward the upright position 28 during the arrow segment 236, the forward rotation of the seat back 16 is not damped because the clock spring 142 is engaged with the actuation bracket 106 and the damper roller 122 is disengaged from the roller engagement area 204 on the leaf spring 182. Fig.13 and Fig.14 After the upright position shown in , the seat back 16 is re-locked.

[0052] When the rotary damper 10 is in an upright state ( Fig.13 and Fig.14 ), the protrusion 146 on the clock spring 142 frictionally engages the engagement surface 114 on the actuation protrusion 112 and is spaced apart from the front surface 134 of the spring stop 132. The protrusion 146 on the clock spring 142 continues to exert a clockwise spring force (arrow 232) on the actuation protrusion 112. However, the seat back 16 remains in the upright position 28 while the seat back 16 is in the locked state. In addition, the damper roller 122 frictionally engages the minimum damping position 212 along the roller engagement area 204 on the leaf spring 182. As shown in FIG. Fig.14As observed in FIG. 1 , the leaf spring 182 applies a counterclockwise damping force (arrow 237) to the damper roller 122 in a rearward rotational direction when the damper roller 122 contacts the leaf spring 182. The magnitude of the counterclockwise damping force (arrow 237) applied to the damper roller 122 is based in part on the relative position of the damper roller 122 along the roller engagement region 204, wherein a minimum damping force is applied near the minimum damping position 212 and a maximum damping force is applied near the maximum damping position 214. In addition, the minimum damping force is less than the maximum damping force. It will be appreciated that the magnitude of the counterclockwise damping force (arrow 237) applied along the roller engagement region 204 can be adjusted by adjusting the profile and relative position of the curved portion 200 of the leaf spring 182.

[0053] When the seat back 16 is in the upright position 28 ( Fig.12 ) and in a locked state, wherein the rotary damper 10 is in an upright state ( Fig.13 and Fig.14 ), the occupant initiates the fold-flat process by unlocking the seat back 16. After the seat back 16 is unlocked, the clockwise spring force (arrow 232) applied by the clock spring 142 to the actuation protrusion 112 causes the seat back 16 to pivot in the forward direction (arrow 234) toward the fold-flat position 29, as shown in FIG. Fig.12 This is further illustrated by arrow segment 238. Fig.14 , the leaf spring 182 applies a minimum counterclockwise damping force (arrow 237) to the damper roller 122 because the damper roller 122 contacts the minimum damping position 212 along the roller engagement zone 204. The seat back 16 continues to rotate in the forward direction (arrow 234) because the minimum damping force (arrow 237) in the counterclockwise direction is less than the clockwise spring force (arrow 232) applied by the clock spring 142. The forward rotation (arrow 234) of the seat back 16 during the arrow section 238 after the clock spring 142 is disengaged from the actuation protrusion 112 and before the damper roller 122 is engaged with the leaf spring 182 is generally an undamped forward rotation. It will be appreciated that the damper roller 122 may engage with the leaf spring 182 before or after the clock spring 142 is disengaged from the actuation protrusion 112 without changing the scope of the present invention.

[0054] Reference Fig.15 , when the seat back 16 rotates through the vertical position 240 (at Fig.12241 and further described as the fold flat transition position), the protrusion 146 on the clock spring 142 frictionally engages the front surface 134 of the spring stop 132 and disengages from the actuation protrusion 112. After the clock spring 142 engages the spring stop 132, the clock spring 142 no longer applies a clockwise spring force (arrow 232) to the actuation protrusion 112. After the seat back 16 rotates forward (arrow 234) past the vertical position 240, gravity causes the seat back 16 to continue to rotate forward toward the fold flat position 29, as shown in FIG. Fig.12 The forward rotation of the seat back 16 in response to gravity during the arrow section 242 (arrow 234) also causes the actuation protrusion 112 to rotate clockwise (arrow 233) past the spring stop 132, as shown in FIG. Fig.15 Observed in .

[0055] Reference Fig.12 If the forward rotational speed of the seat back 16 is not damped, the weight of the seat back 16 will cause the forward rotational speed of the seat back 16 to increase as the seat back 16 rotates through the vertical position 240 (seat back position 241), rotates through the intermediate rotational position (shown as seat back position 243), and rotates toward the fold flat position 29. As the seat back 16 rotates toward the fold flat position 29, the leaf spring 182 in the rotary damper 10 applies a counterclockwise damping force (arrow 237) configured to slow the forward rotational speed of the seat back 16. Additionally, as the seat back 16 approaches the fold flat position 29 (shown as seat back position 243), the leaf spring 182 applies a maximum amount of counterclockwise damping force (arrow 237). Thus, as the seat back 16 approaches the fold flat position 29, the rotary damper 10 applies a full damping effect.

[0056] Reference Fig.16 and Fig.17 , when the actuating protrusion 112 responds to the seat back 16 in the arrow section 242 ( Fig.12), the damper roller 122 travels in a clockwise direction toward the maximum damping position 214 along the roller engagement area 204 (arrow 244). The counterclockwise damping force (arrow 237) applied by the leaf spring 182 to the damper roller 122 damps the clockwise rotation (arrow 233) of the actuation protrusion 112, which also dampens the forward rotation speed of the seat back 16. When the damper roller 122 engages the maximum damping position 214 on the leaf spring 182 and when the seat back 16 is near the folded flat position 29, the maximum amount of counterclockwise damping force (arrow 237) is applied to the damper roller 122. When the seat back 16 rotates through the arrow section 242 , the seat back 16 has dampened forward rotation because the clock spring 142 is disengaged from the actuation protrusion 112 and the damper roller 122 is engaged with the leaf spring 182 .

[0057] The process is reversed to return the seat back 16 from the folded flat position 29 to the upright position 28. Fig.12 , when the seat back 16 is in the folded flat position 29, the occupant rotates the seat back 16 in the rearward rotation direction (arrow 234'), which returns the seat back 16 to the upright position 28. When the seat back 16 is rotated rearward (arrow 234'), the clock spring 142 does not apply a spring force to the seat back 16 in the forward direction, and the clock spring 142 engages the spring stop 132 and disengages from the actuation protrusion 112. When the seat back 16 returns to the upright position 28, the clock spring 142 disengages from the spring stop 132 and engages with the actuation protrusion 112. Next, when the seat back 16 returns to the upright position 28, the locking mechanism is re-locked.

[0058] exist Fig.18 and Fig.19 A second embodiment of a rotary damper 10' is shown in FIG. 1 , wherein like primed reference numerals denote elements similar to those described above. The second embodiment rotary damper 10' includes a modified pivot pin 54' having a spring slot 246 and a circlip 248 fixedly coupled to the pivot pin 54'. Only the significant differences between the two embodiments are reflected in the drawings and the following description.

[0059] Reference Fig.18 and Fig.19 , the pivot pin 54' includes a spring slot 246 that extends radially through the spring spindle 68' and has opposing slot walls 250, 252. The inner end 144' of the clock spring 142' is inserted into the spring slot 246 in the spring spindle 68', which fixedly couples the inner end 144' of the clock spring 142' to the pivot pin 54'.

[0060] like Fig.18 As depicted in , the rotary damper 10' also includes a circlip 248 configured to frictionally engage the outboard end 58' of the pivot pin 54'. During assembly, the outboard end 58' of the pivot pin 54' is inserted through the pivot hole 160' in the outboard cover 154'. Next, the circlip 248 is pressed onto the outboard end 58' of the pivot pin 54 to pivotally couple the outboard cover 154' to the pivot pin 54'.

[0061] As discussed above, the rotary damper 10, 10' of the present invention includes: a leaf spring 182 fixedly coupled to the inner cover 30, which is fixedly coupled to the cushion bracket 22 on the seat assembly 12; a pivot pin 54, 54', which is fixedly coupled to the inner cover 30; an actuation bracket 106, which is pivotally coupled to the pivot pin 54, 54'; and a clock spring 142, which has one end fixedly coupled to the pivot pin 54, 54' and an outer end 148 configured to rotationally bias the actuation bracket 106. In addition, the rotary damper 10, 10' includes a damper roller 122, which is operatively coupled to the actuation bracket 106 and is configured to frictionally engage with the leaf spring 182 when the actuation bracket 106 rotates. In addition, the rotary damper 10, 10' includes an outer side cover 154 that is pivotally coupled to the pivot pin 54, 54', fixedly coupled to the actuation bracket 106, and fixedly coupled to the side bracket 25 of the seat assembly 12. The rotary damper 10, 10' also includes a spring stop 132 that is configured to disengage the clock spring 142 from the actuation bracket 106 when the actuation bracket 106 rotates. In operation, the rotary damper 10, 10' is configured to spring bias the seat back 16 from the reclined position 27 toward the upright position 28, and then dampen the forward rotational speed of the seat back 16 when the seat back 16 rotates from the upright position 28 toward the folded flat position 29.

[0062] The present invention has been described in an illustrative manner, and it should be understood that the terms that have been used are intended to have the nature of descriptive words rather than restrictive words. In view 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 rotary damper for a vehicle seat assembly, comprising: inner cover; a pivot pin fixedly coupled to the inner cover; an actuation bracket pivotably coupled to the pivot pin and including an actuation protrusion; a leaf spring having a head end fixedly coupled to the inner cover and a free end spaced apart from the head end; a damper roller coupled to the actuation bracket and configured to selectively engage with the leaf spring when the actuation bracket is rotated in a forward rotational direction and to disengage from the leaf spring when the actuation bracket is rotated in a rearward rotational direction opposite the forward rotational direction; as well as an outer side cover pivotably coupled to the pivot pin and fixedly coupled to the actuation boss such that the outer side cover and the actuation bracket rotate together; Wherein, when the outer cover rotates relative to the inner cover in the forward rotation direction, the rotation damper damps the rotation speed of the outer cover when the damper roller is engaged with the leaf spring, and the rotation speed is not damped when the damper roller is disengaged from the leaf spring.

2. The rotary damper according to claim 1, wherein: The leaf spring includes a roller engagement region extending along a portion of the leaf spring; and The leaf spring applies a damping force to the damper roller in the rearward rotational direction when the damper roller engages the roller engagement region.

3. The rotary damper according to claim 2, wherein: The roller engagement region includes a minimum damping position spaced from a maximum damping position; and The amount of damping force applied to the damper roller by the leaf spring in the rearward rotational direction is greater when the damper roller is engaged with the maximum damping position than when the damper roller is engaged with the minimum damping position.

4. The rotary damper according to claim 3, wherein: When the damper roller is frictionally engaged with the maximum damping position, a greater amount of damping of the rotational velocity applied by the rotational damper when the outer cover rotates relative to the inner cover in the forward rotational direction is achieved when the damper roller is frictionally engaged with the maximum damping position than when the damper roller is frictionally engaged with the minimum damping position.

5. The rotary damper according to claim 4, further comprising: a clock spring having an inner end fixedly coupled to the pivot pin and an outer end configured to frictionally engage the actuation protrusion; Wherein, the clock spring spring biases the actuation bracket in the forward rotational direction when the outer end portion frictionally engages the actuation protrusion.

6. The rotary damper according to claim 5, wherein: The clock spring biases the outer cover spring to rotate in the forward rotational direction when the outer end portion frictionally engages the actuation protrusion.

7. The rotary damper according to claim 6, further comprising: a spring stop fixedly coupled to the inner cover and configured to frictionally engage the outer end of the clock spring; wherein when the outer end of the clock spring engages with the actuation protrusion and disengages from the spring stop, the clock spring spring biases the outer side cover in the forward rotational direction; and Wherein, when the outer end of the clock spring engages with the spring stopper, the clock spring is disengaged from the actuating protrusion.

8. The rotary damper according to claim 7, wherein: The damper roller includes a roller pin extending axially through the roller; and The roller pin includes one end fixedly coupled to the actuation bracket and an opposite end fixedly coupled to the outer side cover.

9. The rotary damper according to claim 8, wherein: The inner cover is configured to be fixedly coupled to a first component of the seat assembly; The outer side cover is configured to be fixedly coupled to a second component of the seat assembly; and One or more of the first component and the second component is pivotable relative to the other of the first component and the second component; wherein the rotational damper damps the rotational velocity when one of the first component and the second component pivots relative to the other of the first component and the second component and the damper roller engages the roller engagement region on the leaf spring.

10. The rotary damper according to claim 8, wherein: The inner cover includes an inner side wall, a cylindrical wall extending circumferentially around the inner side wall, and a groove extending circumferentially along a portion of the cylindrical wall; and The leaf spring extends through the slot.

11. A seat assembly for use in a motor vehicle, comprising: Seat cushions; a seat back pivotally coupled to the seat cushion and pivotable between a first seat back position and a second seat back position; as well as a rotary damper operatively coupled between the seat back and the seat cushion and comprising: an inner cover fixedly coupled to the seat cushion; a pivot pin fixedly coupled to the inner cover; an actuating bracket pivotally coupled to the pivot pin and comprising an actuating projection; a leaf spring having a head end fixedly coupled to the inner cover and a free end spaced apart from the head end; a damper roller coupled to the actuating bracket and configured to selectively engage with the leaf spring when the actuating bracket rotates in a forward rotational direction; and an outer cover pivotally coupled to the pivot pin, fixedly coupled to the actuating projection so that the outer cover and the actuating bracket rotate together, and fixedly coupled to the seat back; Wherein, when the seat back rotates in the forward rotation direction, the rotation damper damps the rotation speed of the seat back when the damper roller is engaged with the leaf spring, and the rotation speed is not damped when the damper roller is disengaged from the leaf spring.

12. The seat assembly of claim 11, wherein: The leaf spring includes a roller engagement region extending along a portion of the leaf spring; and The leaf spring applies a damping force to the damper roller in a rearward rotational direction opposite to the forward rotational direction when the damper roller engages the roller engagement region.

13. The seat assembly of claim 12, wherein: The roller engagement region includes a minimum damping position spaced from a maximum damping position; and The amount of damping force applied to the damper roller by the leaf spring in the rearward rotational direction is greater when the damper roller is engaged with the maximum damping position than when the damper roller is engaged with the minimum damping position.

14. The seat assembly of claim 13, wherein: A greater amount of damping of the rotational velocity applied by the rotary damper when the seat back rotates relative to the seat cushion in the forward rotational direction is achieved when the damper roller is frictionally engaged with the maximum damping position than when the damper roller is frictionally engaged with the minimum damping position.

15. The seat assembly of claim 14, the rotary damper further comprising: a clock spring having an inner end fixedly coupled to the pivot pin and an outer end configured to frictionally engage the actuation protrusion; Wherein, the clock spring spring biases the actuation bracket in the forward rotational direction when the outer end portion frictionally engages the actuation protrusion.

16. The seat assembly of claim 15, the rotary damper further comprising: a spring stop fixedly coupled to the inner cover and configured to frictionally engage the outer end of the clock spring; wherein when the outer end of the clock spring engages with the actuation protrusion and disengages from the spring stop, the clock spring spring biases the outer side cover in the forward rotational direction; and Wherein, when the outer end of the clock spring engages with the spring stopper, the clock spring is disengaged from the actuating protrusion.

17. The seat assembly of claim 16, wherein: The damper roller includes a roller pin extending axially through the roller; and The roller pin includes one end fixedly coupled to the actuation bracket and an opposite end fixedly coupled to the outer side cover.

18. The seat assembly of claim 11 further comprising a second rotary damper operatively coupled between the seat back and the seat cushion.

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