One seat

Abstract

A seating system may comprise a seat base support with an adjustable support comprising at least one adjuster, a drive mechanism connected to the adjustable support, a slider connected to the drive mechanism, and at least one strip of material extending through the at least one adjuster of the adjustable support and the slider to cause shape changes of the adjustable support when the drive mechanism moves the slider.

Description

TITLEA SEATFIELD

[0001] The presently disclosed subject matter relates to a seat which may be used in a vehicle.BACKGROUND

[0002] Conventional seats, particularly those employed in a vehicle, may include a seat back assembly connected to a seat base assembly and a headrest assembly. The seat base assembly may include a seat cushion length extender. Prior art seat cushion length extenders require multiple high-cost components. Further, the complexity of the prior art seat cushion length extenders requires intricate manufacturing and assembly processes which increases seat cost. For this reason, cushion extenders are typically only offered as an option in premium or high-end vehicles.

[0003] A further drawback of conventional seat cushion length extenders is that they only actuate a middle portion of the cushion, which is supposed to accommodate taller occupants, but these systems do not necessarily extend across a wide enough portion of the cushion to accommodate for leg splay of the occupants. As such, the taller occupants, even with the typical seat cushion length extenders deployed, do not obtain optimized support and comfort rear of the knee when seated in a natural manner. There is also a need for the seat cushion length extenders to retract to provide smaller occupants appropriate leg support and leg clearance in order for the small occupant to bend their legs without interference.

[0004] In view of the disadvantages associated with the prior art, it would be advantageous to provide a seat cushion length extender that provides the possibility for full seat width comfort and accommodation for varying sizes of occupants, without part complexity, while maintaining an integrated appearance when trimmed. The new cushion length adjuster should also minimize expense and complexity of the prior art designs.SUMMARY

[0005] In one embodiment a seat system may have a seat base substrate having an adjustable support comprising at least one adjuster, a drive mechanism connected to the adjustable support, a pusher connected to the drive mechanism and at least one strip of material extending through a portion of the adjustable support and the pusher for effecting shape changes to the adjustable support when the drive mechanism moves the pusher.

[0006] In another aspect the adjustable support may comprise a plurality of adjusters in a grid across a front portion of the adjustable support, where at least some of the adjusters extend through a thickness of the front portion.

[0007] In another aspect the strip of material may extend through a first adjuster, across a portion of the front portion of the adjustable support, and through a second adjuster.

[0008] In another aspect, the strip of material may extend from the second adjuster through the pusher and the strip of material is secured to the pusher.

[0009] In another aspect, the strip of material may extend across the plurality of adjusters in an initial linear path across the front portion of the adjustable support.

[0010] In another aspect, the strip of material may extend through some adjusters and over some adjusters.

[0011] In another aspect, the at least one strip of material may be a loop having a first end and a second end wherein the ends are secured to a rear surface of the pusher.

[0012] In another aspect, the at least one strip of material may be a unitary, one-piece and integrally formed deformable, stretch-resistant ribbon.

[0013] In another aspect, the at least one strip of material may comprise a first strip of material and a second strip of material, wherein the first and second strips are laterally spaced apart from one another across the pusher and extend through different adjusters of the grid.

[0014] In another aspect, the at least one strip of material may comprise a first end portion attached to a rear surface of the pusher, a rear, inner portion extendingfrom the first end portion and behind the pusher, an outer portion extending along an upper outer surface of the pusher, and a front portion extending to a second end portion that connects with the first end portion and the rear surface of the pusher.

[0015] In another aspect, the at least one strip of material may be at least partially constructed of nylon.

[0016] In another aspect, a bottom surface of the strip of material may be in direct facing contact with an outer surface of the adjustable support.

[0017] In another aspect, the at least one the strip of material may extend through a support cantilevered off a rear surface of the pusher.

[0018] In another aspect, the at least one strip of material selectively urges the adjustable support between an extended position and a curled position, in which the adjustable support is at least partially folded on itself.DESCRIPTION OF FIGURES

[0019] FIG. 1 is a schematic perspective view of one embodiment of a seat system with an extended seat base assembly;

[0020] FIG. 2 is a schematic perspective view of one embodiment of a seat system with a retracted seat base assembly;

[0021] FIG. 3 is a schematic side view of the seat base assembly in the retracted condition;

[0022] FIG. 4 is a schematic side view of the seat base assembly in the extended condition;

[0023] FIG. 5 is a schematic upper perspective view of components of the seat base assembly in an extended condition;

[0024] FIG. 6 is a schematic upper perspective view of components of the seat base assembly in a retracted condition;

[0025] FIG. 7 is a schematic lower perspective view of components of the seat base assembly in an extended condition;

[0026] FIG. 8 is a schematic lower perspective view of components of the seat base assembly in a retracted condition;

[0027] FIG. 9 is a schematic lower perspective view of components of the seat base assembly in an extended condition;

[0028] FIG. 10 is a schematic lower perspective view of components of the seat base assembly in a retracted condition;

[0029] FIG. 11 is a schematic upper perspective view of one embodiment of a seat base substrate;

[0030] FIG. 12 is a schematic lower perspective view of one embodiment of a seat base substrate;

[0031] FIG. 13 is a schematic upper perspective cutaway view of components of the seat base assembly in an extended condition;

[0032] FIG. 14 is a schematic upper perspective cutaway view of components of the seat base assembly in a retracted condition;

[0033] FIG. 15 is a schematic cutaway side view of components of the seat base assembly in an extended condition;

[0034] FIG. 16 is a schematic cutaway side view of components of the seat base assembly in a retracted condition;

[0035] FIG. 17 is a schematic cutaway side view of components of the seat base assembly in an extended condition;

[0036] FIG. 18 is a schematic cutaway side view of components of the seat base assembly in a retracted condition;

[0037] FIG. 19 is a schematic upper perspective view of components of the seat base assembly in an extended condition;

[0038] FIG. 20 is a schematic upper perspective view of components of the seat base assembly in a retracted condition;

[0039] FIG. 21 is a schematic upper perspective view of components of the seat base assembly in an extended condition;

[0040] FIG. 22 is a schematic upper perspective view of components of the seat base assembly in a retracted condition;

[0041] FIG. 23 is a schematic perspective view of components of the seat base assembly;

[0042] FIG. 24 is a schematic perspective view of components of the seat base assembly;

[0043] FIG. 25 is a schematic perspective view of components of the seat base assembly;

[0044] FIG. 26 is a schematic perspective view of components of the seat base assembly;

[0045] Fig. 27 is a schematic perspective view of components of the seat base assembly;

[0046] FIG. 28 is a schematic cutaway side view of components of the seat base assembly in an extended position; and

[0047] FIG. 29 is a schematic cutaway side view of components of the seat base assembly in a retracted position.DETAILED DESCRIPTION

[0048] It is to be understood that the presently disclosed subject matter may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the concepts herein. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

[0049] FIGS. 1 and 2 show a seat system 30 for a motor vehicle (not depicted) according to an embodiment of the presently described subject matter. The seat system 30 may extend along a longitudinal direction X of the vehicle, a vertical direction Y of the vehicle and a lateral direction Z of the vehicle. The longitudinal direction may be such as along a common travel direction of the vehicle such as forward and reverse. The lateral direction may be such as side to side and the vertical direction may be such as from the floor to the roof of the vehicle. It canreadily be appreciated that while one set of directions is mentioned for the seat system 30, the seat system 30 may be angled or tilted within a vehicle offset from these directions. Further, the seat system 30 may be used in applications other than motor vehicles.

[0050] The seat system 30 may comprise a seat base assembly 32, a seat back assembly 34, and a headrest assembly 36. The seat back assembly 34 may be coupled to the seat base assembly 32 and the headrest assembly 36. In certain embodiments, the seat base assembly 32 may be movable relative to a floorboard (not shown) of the vehicle, the seat back assembly 34 may be movable relative to the seat base assembly 32, and the headrest assembly 36 may be movable relative to the seat back assembly 34. The seat base assembly 32 may be configured to support a buttock portion and leg portion of an occupant while the seat back assembly 34 may be configured to support a back region of the occupant.

[0051] The seat system 30 may also include a seat frame (not shown) comprising a seat base frame portion (not shown), a seat back frame portion (not shown), and a headrest frame portion (not shown). The frame portions may be movingly coupled together using any suitable means as desired. Any suitable material may be employed to produce the frame portions as desired. For example, each of the frame portions may be formed from a rigid metal material.

[0052] FIGS. 1 -4 depict the seat base assembly 32 in two conditions. The two conditions are a longitudinally retracted condition and a longitudinally extended condition. The seat base assembly 32 may also exist in any longitudinal condition between the retracted and extended condition. The seat base assembly 32 may also have tilt, bolster, swivel and other adjustments.

[0053] The adjustable seat base assembly 32 can accommodate a wide variety of occupants regardless of their size or shape. Via the structures and operations described herein the adjustable seat base assembly 32 can provide full longitudinal under-leg support across the width of the seat base assembly 32 that may be needed for occupants of various sizes and shapes.

[0054] The seat base assembly 32 may include a seat base substrate 38 coupled to the seat base frame portion, an optional cushioning member (discussed later) disposed on the seat base substrate 38, and a seat cover 40 disposed over the cushioning member and / or seat base substrate 38.

[0055] FIGS. 5-12 depict one embodiment of the seat base substrate 38. The seat base substrate 38 may be a single, one-piece component, however, the seat base substrate 38 may be a multi-piece component if desired. In certain embodiments, the seat base substrate 38 may be configured with a size and shape to cooperate with a rigid seat base structure such as the seat base frame portion. The seat base substrate 38 may be formed of an elastomeric material such as a thermoplastic elastomer (TPE) material. Various types of the TPE material may be employed such as at least one of a styrenic block copolymer, thermoplastic olefinic elastomer, and / or thermoplastic vulcanisate.

[0056] In certain embodiments, the seat base substrate 38 provides conforming support that flexes with the size, shape and / or posture of the occupant and accommodates differently sized occupants with less need for active adjustments to the seat system 30. In certain embodiments, the seat base substrate 38 may have a flexural modulus in a range of about 200 MPa to about 800 MPa, preferably about 290 MPa, and a tensile modulus in a range of about 10 MPa to about 300 MPa, preferably about 280 MPa. It is understood that the seat base substrate 38 may be formed from any suitable material having a desired flexural modulus. It is further understood that the seat base substrate 38 may be formed by any suitable method as desired such as an injection molding process, a thermoforming process, a compression molding process, a blow molding process, a vacuum casting process, a three-dimensional printing process, and the like.

[0057] The seat base substrate 38 formed from the TPE material may exhibit both thermoplastic and elastomeric properties which permit flexibility of the seat base substrate 38 while militating against a permanent set thereof. As such, the seat base substrate 38 has an ability to stretch to moderate elongations and return to an original shape. Hence, the seat base substrate 38 may be relatively thin as compared to commonly known seat base substrates. In certain embodiments, athickness of the seat base substrate 38 may be in a range of about 1 mm to about 5 mm, preferably in a range of about 1 .5 mm to about 3.0 mm, and more preferably about 2 mm or less.

[0058] Since the seat base substrate 38 adapts to the occupant with conforming support, a cushioning member 42 may or may not be used in whole or in part with the seat base substrate 38. One embodiment of a cushioning member may be seen in Fig 15. When a cushioning member 42 is used, it may be relatively thin as compared to commonly known cushioning members due to the comfort provided by the seat base substrate 38. In certain embodiments, a thickness of the cushioning member 42 may be in a range of about 15 mm to about 25 mm, preferably 20 mm or less.

[0059] In other embodiments, the seat base substrate 38 formed from the TPE material may eliminate a need for the cushioning member in the seat base assembly 32. As a non-limiting example, a thickness of the seat base assembly 32 may be about 45 mm less than commonly known seat base assemblies. Accordingly, in certain embodiments, the seat base substrate 38 results in a reduction in mass and size of the seat base assembly 32 as compared to commonly known seat base assemblies. Such a reduction in the mass and size of the seat base assembly 32 improves manufacturability and decreases costs, while maintaining comfortability. Furthermore, the seat base assembly 32 minimizes a consumption of valuable space within a passenger compartment of the vehicle. As a result, a size of the passenger compartment of the vehicle, and therefore, a size of the vehicle in its entirety, may be reduced, which also results in a reduction in mass and energy consumption of the vehicle. It should be appreciated that each of the seat base substrate 38, the cushioning member 42, and the seat base assembly 32 may have any thickness as desired.

[0060] From the above, it can be appreciated that the seat base substrate 38 may function alone as both a suspension for the seat system 30 as well as a structural component of the seat system 30. For example, it may be that other springs or biasing members are not required with the seat base assembly 32 to provide a suspension between the seat frame. Further, it may be that no otherwire seat support structures or structural members are required for the seat base assembly 32 between the seat frame.

[0061] The seat base substrate 38 includes a front portion 44, a rear portion 46, a first side portion 48 and a second side portion 50. The seat base substrate 38 further includes a main support portion 52 formed between the front and rear portions 44, 46 and between the first and second side portions 48, 50.

[0062] As best seen in FIGS. 5-12, the seat base assembly 32 may further include an adjustable support 56. The adjustable support 56 may be configured to enhance comfort and enable support for the various driving positions and body size of the occupant. Additionally, the adjustable support 56 provides simplified execution combined with improved functionality and usability over the prior art. As a non-limiting example, the adjustable support 56 may be configured to be selectively extended behind knees of an occupant having a larger body size with legs naturally splayed. As another non-limiting example, the adjustable support 56 may be configured to be selectively retracted behind knees of an occupant having a smaller body size so as not to interfere with the back of the calves of the occupant. In certain embodiments, the adjustable support 56 may laterally extend entirely, or just a portion of, the seat base assembly 32 to provide a desired comfort, support and / or accommodate leg splay of the occupant. At least a portion of the adjustable support 56 may be formed from the same material as the seat base substrate 38. In some embodiments, the adjustable support 56 may be unitary, one-piece and integrally formed with the seat base substrate 38.

[0063] The adjustable support 56 may have slots extending entirely or partially through the thickness of the support 56. The adjustable support 56 may also have relief cuts such as along a perimeter 58 of the adjustable support 56. Together these items will be designated as adjusters 60. The adjusters 60 may be in any number and have any shape, size, and configuration as desired. The adjusters 60 can be located at predetermined locations and in any number to tune the adjustable support 56 to the application. For example, the adjusters 60 might be used to control at least one of rigidity / flexibility, shape, and conformability of the adjustable support 56. For example, the adjusters 60 might be used to increaseor decrease the flexibility of the adjustable support 56 and / or increase an airflow through and around the adjustable support 56 for the comfort of the occupant. In one embodiment, the adjusters 60 may be generally aligned in one or more grid patterns 62 in the adjustable support 56 having one or more rows 64 and one or more columns 66. The rows / columns 64, 66 may vary as they extend across the grid pattern 62.

[0064] The adjustable support 56 may be attached to the seat frame or components of the seat frame, such as a seat pan 68. As shown in FIG. 7, the adjustable support 56 may have a portion that extends through the seat pan 68 to secure them together. In the embodiment shown in FIG. 7, the adjustable support 56 may have feet 70 that extend through apertures 72 in the seat pan 68 to secure the adjustable 56 support to the seat pan 68.

[0065] FIGS. 11 and 12 depict another embodiment of the seat base substrate 38 and / or adjustable support 56. In this embodiment, the seat base substrate 38 may essentially comprise the adjustable support 56 and a connection portion 74. The connection portion 74 may be attached to the seat base frame or structures attached to the seat base frame.

[0066] In certain embodiments, the adjustable support 56 is selectively positionable between an extended position 76, shown in FIG. 4 and a retracted position 78, shown in FIG 6. A drive mechanism 80, one embodiment of which is partially depicted in FIGS. 7-10, may be employed to cause the adjustable support 56 to be selectively positioned anywhere between the extended position 76 and the retracted position 78.

[0067] The drive mechanism 80 may be manual, automatic, or partially automatic. The drive mechanism 80 may be in electrical communication with a controller (not depicted) and a power source (not depicted). The drive mechanism 80 may be disposed under or within the base seat assembly 32 but it may be located elsewhere too.

[0068] The drive mechanism 80 may be engaged by the occupant via one or more buttons 82 on a side panel 84 of the seat base assembly 32. In otherembodiments, the drive mechanism 80 may be engaged by one or more sensors in the seat base assembly 32, and / or by voice, touch screen or remote operation.

[0069] The drive mechanism 80 may be comprised of one or more electric motors but pneumatics, hydraulics and / or other biasing members may be used. In each case, it is preferred that the drive mechanism 80 be reversible so that it provides motion along both longitudinal directions.

[0070] The drive mechanism may also include a linkage 86 and a pusher 88. The linkage 86 may be any device, or devices, that connects the drive mechanism 80 (or other such device) to the pusher 88. The linkage translates the rotational motion output by the drive mechanism 80 into a longitudinal movement of the pusher 88. The pusher 88 may be located along at least a portion of the adjustable support 56. The pusher 88 may be one-piece, unitary and integrally formed, such as of a plastic polymer, metal or any rigid material.

[0071] As may be seen in many of the figures, the seat cover 40 may be connected to the adjustable support 56. FIGS. 13-18 depict some ways a front end portion 90 of the seat cover 40 may be connected to the adjustable support 56.

[0072] For example, the front end portion 90 of the seat cover 40 may be connected to the adjustable support 56 such as through one or more J-strips 92. The front end portion 90 of the seat cover 40 may be attached to a base portion 94 of the J-strip 92. A hook portion, located opposite the base portion 94 of the J- strip 92, may be located through one of the adjusters 60 in the adjustable support 56 to secure it thereto.

[0073] In another embodiment depicted in FIGS. 17-18 the front end portion 90 of the seat cover 40 may be connected directly to the pusher 88. The seat cover 40 may be connected to the pusher 88 such as through one or more J-strips 92. The front end portion 90 of the seat cover 40 may be attached to the base portion 94 of the J-strip 88. The hook portion 96 of the J-strip 92 may be located through an aperture 98 in the pusher 88 to secure the cover to the pusher 88. In both embodiments, a plurality of J-strips 92 may be used to connect the front portion 80 of the cover 40 to the pusher 88 or the adjustable support 56. For example, FIG.8 depicts a plurality of hook portions 96 of various J-strips 92 located through apertures 98 in the pusher 88.

[0074] While one orientation of the J-strips 92 is shown, the J-strips 92 may also be turned 180 degrees so that the hook portion 96 is the lowermost portion. The J-strips 92 can also be attached to a bottom edge 100 of the adjustable support 56.

[0075] The pusher 88 may be connected to the adjustable support 56 through one or more lengths of material 102 as may be appreciated from the various figures. One such example may be seen in such as FIGS. 13-18.

[0076] The material 102 may be such as a woven material, a non-woven material or combinations thereof. The material 102 may be natural or man-made or combinations thereof. In one embodiment, the material 102 may be any material that is flexible, resilient, tough, and stretch and deterioration resistant. The material 102 may also be relatively silent when it moves so it does not contribute buzzes, squeaks, or rattles in the seat system 30. The material 102 also should not create any vibrations, noise or harshness when it moves. As such, the material 102 may need a certain degree of smoothness and / or lubricity so that it moves over the seat structures described below without getting hung-up or paused. Other devices such as wires, ties, and / or mechanical fasteners may be used as well for the material.

[0077] In the woven fabric embodiment, the woven fabric may be such as Nylon, polypropylene or polyethylene. Nylon can be used in whole or in part. Nylon strips may be advantageous for their resilience, resistance to stretch, thinness, flexibility, availability and low cost. Such material may be used in other aspects of a seat system 30 and / or the vehicle, which may make an environmentally safe option in terms of utilizing a material already used in other areas of the vehicle or seat. In another embodiment one or more zip ties (AKA cable tie or Ty-Rap) or sheet stock strips, cords and / or ribbons of polypropylene, polyethylene or polytetrafluoroethylene (PTFE AKA Teflon), or strips of fiberglass fabric may be used.

[0078] In one embodiment the material 102 may have a substantially rectangular overall shape which may provide it with a ribbon-like appearance. In other embodiments, the material 102 may be of various sizes and shapes, in whole or in part. In some embodiments, the material 102 may be one-piece, unitary and integrally formed.

[0079] The material 102 may be approximately ,01 mm to 2 mm thick. The material 102 may have a constant thickness along its length or variations may be possible.

[0080] The material 102 may have a first end portion 104 that is attached to the pusher 88. For example, as seen in FIGS. 15-18 the first end portion 104 of the material 102 may be attached to a rear, lower portion 106 of the pusher 88. The attachment may be such as through a fastener 108.

[0081] The fastener 108 may have a body portion 110 and a head portion 112. The body portion 110 may be located through the first end portion 104 of the material 102 and into an aperture 114 in the rear, lower portion 106 of the pusher 88. The head portion 112 prevents further insertion of the fastener 108 into the material 102 and / or the aperture 114 and it secures the material 102 between the pusher 88 and the fastener 108. In such a case, the material 102 may have a slot 116 for receiving the body portion 110 of the fastener 108 therethrough.

[0082] The material 102 may be comprised of a rear inner portion 118. The rear inner portion 118 may extend behind the pusher 88 where it may develop a curved path and may comprise a slack portion 120 in certain conditions.

[0083] The rear inner portion 118 may extend upwardly through at least one of the adjusters 60 of the adjustable support 56.

[0084] As shown in certain figures, the material 102 may be located through, such as guided, woven and / or threaded through, at least one of the adjusters 60 of the adjustable support 56. In some cases, it may be that the material 102 is located through a longitudinally rearward adjuster 122 in the adjustable support 56. Once through the adjuster 60, an outer portion 124 of material 102 may extend over an outer, upper surface 126 of the adjustable support 56. The extent to which the outer portion 124 of the material 102 may extend over the upper surface 126may be related to the amount of biasing effect the material 102 has on the adjustable support 56.

[0085] In one case, the outer portion 124 of the material 102 may span across the outer, upper surface 126 in a generally linear manner. In such a case, the material 102 may extend over one or more adjusters 60. In other words, the material 102 may extend over one or more openings in the adjuster 60 as well as one or more ribs of the grid pattern 62 formed in the adjustable support 65. The one or more openings and / or ribs that the material 102 extends over may be generally linearly aligned with one another in the adjustable support 56.

[0086] The material 102 may then extend into one of the adjusters 60 of the adjustable support 56. In one case, the material 102 may be guided through a longitudinally forward adjuster 128 so that it extends entirely through the adjuster 60 from the outer, upper surface 126 of the adjustable support 56 to a lower surface 130 of the adjustable support 56.

[0087] In one embodiment, a front portion 132 of the material 102 may extend at least partially between the adjustable support 56 and an outer surface 134 of the pusher 88. The front portion 132 may transition to a second end portion 136 of the material 102.

[0088] The second end portion 136 of the material 102 may be located through an aperture 138 in the pusher 88. Once through the pusher 88, the second end portion 136 of the material 102 may be located in front of or behind the first end portion 104 the material 102, such that the two end portions 64,136 overlap. The second end portion 136 may have a slot 140 to receive the body portion 110 the fastener 108 therethrough. The first and second end portions 104,136 of the material 102 are thus secured to the pusher 88.

[0089] The pusher 88 may selectively move the adjustable support 56. In one embodiment, the pusher 88 causes the adjustable support 56 to move from the extended position 76, shown in FIGS. 15 and 17, to the retracted position 78 shown in FIGS. 16 and 18. The material 102 is designed to accommodate the movement between these positions and in between them.

[0090] In one embodiment, the retraction of the adjustable support 56 may reduce the site of the slack portion 120 in the rear inner portion 118 of the material 102 as the adjustable support 56 curls and draws material 102 out from behind the pusher 88. The material 102 may move along, and deform with, the outer, upper surface 126 of the adjustable support 56. In other words, because the material 102 is flexible and moves, it can occupy different spaces about the pusher 88 and adjustable support 56. The flexible nature of the material 102 may be appreciated in at least Figs. 19 and 20, which depict that material 102 curving and deforming about the pusher 88.

[0091] In the retracted position 78, one embodiment of which is shown in FIGS. 16 and 18, the front portion 132 of the material 102 may have taken on a shape that is substantially complementary to a front surface 142 of the adjustable support 56. In such a case, a rear surface 144 of the front portion 132 of the material 102 may be direct facing contact with the front surface 142 of the adjustable support 56.

[0092] The material 102 may move during the retraction process such that a spanning portion 146 is formed between a lower front portion 148 of the adjustable support 56 and the second end portion 136. The spanning portion 146 may generally extend in the longitudinal direction, as shown in FIGS. 16 and 18.

[0093] The adjustable support 56 and at least a portion of the material 102 may curl as they adjust from the extended position 76 to the retracted position 78, as shown in at least FIGS. 15-18. The curl urges the change in the longitudinal extension of the seat base assembly 32. In other words, the closed loop of material 102 may function to create the curl in the adjustable support 56 as the material 102 draws the adjustable support 56 rearwardly and to a certain extent inwardly on itself. In such a case, the adjustable support 56 may at least partially vertically overlap itself. In this condition the adjustable support 56 may have a general C- shape in cross-section as shown in Figs. 16 and 18. In the extended position 76, the adjustable support 56 may have a J-shape in cross-section. Thus, it can be appreciated that the adjustable support 56 extends not only in the longitudinal direction, but it may also change shape at the same time as it extends.

[0094] In some cases, at least one support 150 may be associated with the pusher 88. One embodiment of a support 150 is depicted in FIGS. 19-20 and 23- 26. The support 150 may be such as a hoop, loop, box or one or more rails connected to a rear surface 152 of the pusher 88 and extending longitudinally rearward. In one embodiment, the support 150 may be integrally formed, one piece and unitary with the pusher 88 such that is it is formed of the same material. In some cases, the support 150 may be cantilevered off the rear surface 152.

[0095] The support 150 may contact the seat pan 68 to provide additional rigidity to the pusher 88, particularly at outer lateral portions 154, if needed in certain embodiments. The contact may be such as slidingly connected to the pusher 88.

[0096] In other embodiments shown in FIGS. 21 and 22 the support 150 can be eliminated. These embodiments also show outboard slots 156 to which the seat cover 40 may be attached directly to the pusher 88, such as through J-strips or the like.

[0097] From FIGS. 19-20 and 23-26 it can be appreciated that the material 102 at least partially extends about the pusher 88. FIGS. 23-26 depict one embodiment where the material 102 extends about the outer upper surface 134 and a front surface 158 of the pusher 88 and also extends through the outer surface 134 through the aperture 138. There may be various vertically aligned apertures 138 located in the outer surface 134 of the pusher 88. The apertures 138 may be the same as one another or they may vary in size and / or shape. In some cases, a vertical channel 160 may connect end portions 162 of the apertures 138. The channel 160 may facilitate movement of the material 102 between the various apertures 138 to adjust the amount of curl provided by the material 102 during a retraction. It may be also that hook portions 164 define part of the apertures 138. The hook portions 164 may be used to retain the material 102 within the aperture 138.

[0098] FIG. 24 depicts one embodiment where a securing device 166 such as a button or snap may be used to secure the two end portions 104,136 of the material 102 together. FIGS. 25-27 depict another embodiment where one endportion 104 or 136 is provided with an integrally formed arrow 168 and the other end portion 104 or 136 is provided with a slot 170 to receive the arrow 168 therein to secure the two end portions 104,136 together. The end portions 104, 136 may also be attached by hook and loop fasteners, an adhesive and / or thermally bonded.

[0099] In another embodiment depicted in Fig. 28, the rear inner portion 118 of the material 102 may be located through an intermediate longitudinal adjuster 172. The intermediate longitudinal adjuster 172 may be located forward of the longitudinally rearward adjuster 122.

[0100] FIG. 29 shows the difference locating the material 102 through different adjusters 60 may have on the components of the seat base assembly 32, such as noted in Fig. 28, when the seat base assembly 32 moves into the retracted condition.

[0101] In FIG. 29, the material 102 has caused the adjustable support 56 to change shape into a deformation pattern 174, such as bow or arch in an upward direction away from the pusher 88 and pan 68. In such an embodiment, the adjustable support 56 may be connected to the pan 68 in a different location than as shown at feature 70. The new connection location may be longitudinally forward from the original connection location, which may predispose the adjustable support 56 into forming the deformation pattern 174 during retraction.

[0102] The deformation pattern 174 of the adjustable support 56 may influence any cushioning material 42, and / or the cover 40, to provide increased vertical support and / or a tilt to the seat system 10.

[0103] The seat cover 40 may extend entirely or partially over the seat base substrate 38 at least in some locations. The seat cover 40, via at least partially its attachment to the pusher 88, remains in an intentionally taut and relatively wrinkle free-condition whether the seat system 30 is located in the extracted position 76 or the retracted position 78 and everything in between.

[0104] The cover 40 may be a single material or it may be comprised of several materials. In some embodiments, a stretch material 176 may be incorporated into the cover 40 to accommodate its movement between the extended and retractedpositions 76,78. The stretch material 176 may assist in reducing noise associated with movement by the cover 40 and in eliminating wrinkles.

[0105] From the foregoing it can be readily appreciated that the seat system 30 can comfortably accommodate a wider range of potential occupants compared with previous seats. For example, by its adjustability, the seat system 30 may accommodate at least a female occupant in the fifth percentile of height and weight and up to but not limited to a male occupant in the ninety-fifth percentile of height and weight.

[0106] While various embodiments have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant arts that the disclosed subject matter may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiments described above are therefore to be considered in all respects as illustrative, not restrictive.

Claims

What is claimed is:1 . A seat system, comprising: a seat base substrate having an adjustable support comprising at least one adjuster; a drive mechanism connected to the adjustable support; a pusher connected to the drive mechanism; and at least one strip of material extending through the at least one adjuster of the adjustable support and the pusher for effecting shape changes to the adjustable support when the drive mechanism moves the pusher.

2. The seat system of claim 1 , wherein the adjustable support comprises a plurality of adjusters in a grid across a front portion of the adjustable support, wherein at least some of the adjusters extend through a thickness of the front portion.

3. The seat system of claim 2, wherein the strip of material extends through a first adjuster, across a portion of the front portion of the adjustable support, and through a second adjuster.

4. The seat system of claim 3, wherein the strip of material extends from the second adjuster through the pusher and the strip of material is secured to the pusher.

5. The seat system of claim 3, wherein the strip of material extends across the plurality of adjusters in an initial linear path across the front portion of the adjustable support.

6. The seat system of claim 3, wherein the strip of material extends through some adjusters and over some adjusters.

7. The seat system of claim 1 , wherein the at least one strip of material is a loop having a first end and a second end wherein the ends are secured to a rear surface of the pusher.

8. The seat system of claim 1 , wherein the at least one strip of material is a unitary, one-piece and integrally formed deformable, stretch-resistant ribbon.

9. The seat system of claim 2, wherein the at least one strip of material comprises a first strip of material and a second strip of material, wherein the first and second strips are laterally spaced apart from one another across the pusher and extend through different adjusters of the grid.

10. The seat system of claim 1 , wherein the at least one strip of material comprises: a first end portion attached to a rear surface of the pusher, a rear, inner portion extending from the first end portion and behind the pusher, an outer portion extending along an upper outer surface of the pusher, and a front portion extending to a second end portion that connects with the first end portion and the rear surface of the pusher.11 . The seat system of claim 1 , wherein the at least one strip of material is at least partially constructed of nylon.

12. The seat system of claim 1 , wherein a bottom surface of the strip of material is in direct facing contact with an outer surface of the adjustable support.

13. The seat system of claim 1 , wherein the at least one the strip of material extends through a support cantilevered off a rear surface of the pusher.

14. The seat system of claim 1 , wherein the at least one strip of material selectively urges the adjustable support between an extended position and a curled position, in which the adjustable support is at least partially folded on itself.

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