Power disc assembly with manual override feature

Abstract

A power recliner assembly for an automotive seat assembly includes an A-bracket (16) with a guide aperture (48), a B-bracket (18), a power disc assembly (12) including a first tooth plate (82) rotatably fixed to the B-bracket and having a first locking feature (112), a second tooth plate (94) rotatably coupled to the first tooth plate, and a drive hub (132) extending axially therethrough. The power recliner assembly also has a manual override assembly (14) which includes a locking wedge (178) having a wedge boss (194) slidably coupled to the guide aperture and a central bore (200) extending axially therethrough. The drive hub extends through the central bore. The locking wedge is movable along the guide aperture between a locked position engaged with the first locking feature which prevents rotation of the A-bracket relative to the B-bracket and an unlocked position disengaged from the first locking feature which allows the A-bracket to rotate relative to the B-bracket.

Description

POWER DISC ASSEMBLY WITH MANUAL OVERRIDE FEATURECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63 / 695,661, filed on September 17, 2024, the disclosure of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates to a power disc assembly for use in a seat assembly of an automotive vehicle. More particularly, the invention relates to a power disc assembly having a manual override feature.DESCRIPTION OF RELATED ART

[0003] Disc locking mechanisms for use in a seat assembly of an automotive vehicle are known in the art. One common type of disc locking mechanism is a power disc assembly. Typical power disc assemblies include a fixed plate and a movable plate rotatably coupled to the fixed plate. The fixed plate is often formed to include a toothed outer profile, and the movable plate is often formed to include a toothed inner profile. The toothed outer profile typically has at least one less tooth than the toothed inner profile. The power disc assembly includes a drive mechanism disposed between the movable plate and the fixed plate and operable for urging the movable plate to rotate relative to the fixed plate. The drive mechanism typically includes a cam and a pair of wedges that define an eccentricity, which presses the toothed outer profile and the toothed inner profile into each other at an engagement point defined by the eccentricity. When the cam is rotated in a first direction or an opposite second direction, the wedges are also driven in the first or second direction, causing the direction of the eccentricity to change and therefore shifts the engagement point of the toothed outer profile in the toothed inner profile. The shifting of the engagement point manifests itself as a wobbling rotational movement of the movable plate in the first or second direction.

[0004] It is common for the seat assembly to include a seat back pivotably coupled to a seat cushion by the power disc assembly. The power disc assembly selectively pivots the seat back between an upright seating position, a reclined seating position, and a fold flat position with the seat back overlying the seat cushion. In certain circumstances, power may be cut off to the seat assembly, which prevents the power disc assembly from repositioning the seat back.

[0005] It is commonly known for seat assemblies to include a secondary external manual latch to allow an occupant to manually rotate the seat back. The secondary external manual latch allows for emergency release of the power disc assembly to allow for occupant egress. Further, the secondary external manual latch allows for rapid adjustment of normally power-operated features, such as pivoting the seat back to the fold flat position.

[0006] However, the secondary external manual latch is an add-on mechanism that is located above the center of rotation of the power disc assembly. Further, shielding may be required to cover the secondary external manual latch.100071 It is desirable for the power disc assembly to include a manual override feature that is aligned with the rotational axis of the power disc assembly. Further, it is desirable to include a manual override function for the power disc assembly without adding a secondary external manual latch.SUMMARY OF THE INVENTION

[0008] According to one embodiment, there is provided a power recliner assembly for a seat assembly for use in an automotive vehicle. The power recliner assembly includes an A-bracket having a guide aperture extending therethrough, a B-bracket, a power disc assembly, and a manual override assembly. The power disc assembly includes a first tooth plate rotatably fixed to the B-bracket and having a first locking feature, a second tooth plate rotatably coupled to the first tooth plate, a center aperture extending axially therethrough, and a cam assembly rotatably mounted between the first tooth plate and the second tooth plate. The power recliner assembly also includes a drive hub extending axially through the center aperture and through the guide aperture and defining a rotational axis. The power recliner assembly also includes a drive shaft driveably coupled to the drive hub. In addition, the manual override assembly includes a locking wedge having a wedge boss slidably coupled to the guide aperture, a central bore extending axially therethrough, and a second locking feature formed in the wedge boss. The drive hub extends at least partially through the central bore. The locking wedge is movable in an axial direction along the guide aperture between a locked position and an unlocked position spaced apart from the locked position. In addition, the first locking feature is fictionally engaged with the second locking feature while the locking wedge is in the locked position, which prevents rotation of the A-bracket relative to the B-bracket. Further, the firstlocking feature is spaced apart from the second locking feature while the locking wedge is in the unlocked position, which allows the A-bracket to rotate relative to the B-bracket.

[0009] The manual override assembly provides a manual latch for the power recliner assembly which is aligned with the rotational axis of the power disc assembly. In addition, the manual override assembly is integrally assembled with the power disc assembly and provides a manual unlatch function without requiring a secondary external manual latch. Further, the manual override assembly assembled in axial alignment with the power disc assembly has an advantage of reducing an overall radial dimension of the combined power disc assembly and the manual latch, which in turn may reduce the amount of shielding required to protect these components and may further result in an overall weight reduction.

[0010] According to another embodiment, there is provided a power recliner assembly for a seat assembly for use in an automotive vehicle. The power recliner assembly includes an A- bracket having a guide aperture extending therethrough, a B-bracket, a power disc assembly, and a manual override assembly. The power disc assembly includes a first tooth plate rotatably fixed to the B-bracket, a second tooth plate rotatably coupled to the first tooth plate and having a first locking feature, a center aperture extending therethrough, and a drive hub extending though the center aperture. The manual override assembly includes a locking wedge having a second locking feature and a central bore extending therethrough. The locking wedge is slidably coupled to the guide aperture and the drive hub extends at least partially through the central bore. The locking wedge is movable along the guide aperture between a locked position and an unlocked position spaced apart from the locked position. The first locking feature is frictionally engaged with the second locking feature while the locking wedge is in the locked position, which prevents rotation of the A-bracket relative to the B-bracket. The first locking feature is spaced apart from the second locking feature while the locking wedge is in the unlocked position, which allows the A-bracket to rotate relative to the B-bracket.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0012] Figure 1 is a left perspective view of a power recliner assembly, according to one embodiment of the present invention;

[0013] Figure 2 is a right perspective view of the power recliner assembly of Figure 1;

[0014] Figure 3 is an exploded view of the power recliner assembly of Figure 2;

[0015] Figure 4 is a cross-sectional view of a power disc assembly of Figure 3, taken along line 4-4 in Figure 2;

[0016] Figure 5 is a right perspective view of the power disc assembly of Figure 4;

[0017] Figure 6 is a left perspective view of a locking wedge retainer of Figure 3;

[0018] Figure 7 is a partially transparent left perspective view of a locking wedge of Figure 3;

[0019] Figure 8 is a partially transparent perspective view of a retractor bushing of Figure 3;

[0020] Figure 9 is a right perspective view of a release lever of Figure 3;

[0021] Figure 10 is a right side view of the power recliner assembly of Figure 2, showing a locked condition;

[0022] Figure 11 is a right side view of the power recliner assembly of Figure 10, showing an unlocked condition;

[0023] Figure 12 is a right perspective cross-sectional view of the power recliner assembly of Figure 10, taken along line 4-4 in Figure 2 and with the manual override assembly in the locked condition;

[0024] Figure 13 is a cross-sectional view of the power recliner assembly of Figure 12, taken along line 4-4 in Figure 2 and with the manual override assembly in the locked condition;

[0025] Figure 14 is a right perspective cross-sectional view of the power recliner assembly of Figure 11, taken along line 4-4 in Figure 2 and with the manual override assembly in the unlocked condition;

[0026] Figure 15 is a cross-sectional view of the power recliner assembly of Figure 14, taken along line 4-4 of Figure 2 and with the manual override assembly in the unlocked condition;

[0027] Figure 16 is a partially transparent right side view of the power recliner assembly of Figure 13 with the manual override assembly in the locked condition;

[0028] Figure 17 is a right side view of a power disc assembly, according to a third embodiment of the present invention; and

[0029] Figure 18 is left side view of a locking wedge, according to the third embodiment of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0030] Figures 1-18 illustrate a power recliner assembly 10 having a power disc assembly 12 and a manual override assembly 14 for use in an automotive seat assembly, according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0031] Figures 1-16 illustrate the power recliner assembly 10, according to a first embodiment of the present invention. Depicted in Figures 1-3, the power recliner assembly 10 includes the power disc assembly 12, an A-bracket 16, a B-bracket 18, a rotational axis 20, an electric motor 22, and a drive shaft 24. The power disc assembly 12 is configured to selectively rotate one of the A-bracket 16 and B-bracket 18 relative to the other one of the A-bracket 16 and the B- bracket 18 around the rotational axis 20 of the power disc assembly 12. In the first embodiment, the B-bracket 18 is rotationally fixed, and the A-bracket 16 is rotatably coupled to the B-bracket 18 via the power disc assembly 12. It will be appreciated that the A-bracket 16 might be rotationally fixed, with the B-bracket 18 rotatable relative to the A-bracket 16 without altering the scope of the present invention. Depicted in Figure 1, the electric motor 22 is fixedly coupled to the A-bracket 16 and driveably coupled to the drive shaft 24, as is commonly known in the art. The mounting location of the electric motor 22 might vary without altering the scope of the present invention. The electric motor 22 is omitted from the remaining Figures to improve clarity. Further, components of the power recliner assembly 10 which have a respective axis aligned with the rotational axis 20 of the power disc assembly 12 are shown having a common rotational axis 20.

[0032] As described in more detail below, the drive shaft 24 is driveably coupled to the A- bracket 16 and axially aligned with the rotational axis 20. Depicted in Figures 1-3, the drive shaft 24 includes a shaft surface 26, an outboard end 28, an inboard end 30, a spline feature 32,and a clip groove 34. The shaft surface 26 extends circumferentially around the rotational axis 20 between the outboard end 28 and the opposing inboard end 30. Further, the spline feature 32 extends in an axial direction along the shaft surface 26. The clip groove 34 extends in a circumferential direction along the shaft surface 26 of the drive shaft 24 and is spaced adjacent to the inboard end 30.

[0033] Depicted in Figure 3, the A-bracket 16 has an elongated shape and includes an inboard surface 36, an outboard surface 38, a forward-facing portion 40, a rearward-facing portion 42, a flange 44, and a spring hole 46. The inboard and outboard surfaces 36, 38 oppose each other and extend between the forward-facing and rearward-facing portions 40, 42. The flange 44 extends at least partially along a perimeter of the A-bracket 16 and projects axially away from the inboard surface 36. The spring hole 46 extends axially through the A-bracket 16 between the inboard and outboard surfaces 36, 38.

[0034] The A-bracket 16 also includes a guide aperture 48 extending axially therethrough and spaced apart from the spring hole 46. The guide aperture 48 has a generally bow-tie shape extending axially between the inboard and outboard surfaces 36, 38 with the bow-tie shape defining a guide axis 49. In addition, the guide aperture 48 is axially aligned with the rotational axis 20. In more detail, the guide aperture 48 includes a forward segment 50, a rearward segment 52, an upper segment 54, a lower segment 56, a front wall 58, a rear wall 60, a forward wall 62, a rearward wall 64, an upper slot 66, and a lower slot 68. The forward and rearward segments 50, 52 extend circumferentially between a lower end of the adjacent front and rear walls 58, 60 and an upper end of the adjacent forward and rearward walls 62, 64, respectively. The upper slot 66 is bounded by the upper segment 54, the front wall 58, and the rear wall 60. The lower slot 68 bounded by the lower segment 56, the forward wall 62, and the rearward wall 64. It will be appreciated that the guide aperture 48 along with the upper and lower slots 66, 68 might vary in shape without altering the scope of the present invention.

[0035] Depicted in Figures 1-3, the B-bracket 18 has an elongated shape and includes a n inboard wall 70, an outboard wall 72, a forward side 74, a rearward side 76, an outer flange 78, and a recliner hole 80. The inboard and outboard walls 70, 72 oppose each other and extend between the forward and rearward sides 74, 76. The outer flange 78 extends at least partially along a perimeter of the B-bracket 18 and projects axially away from the outboard wall 72. The recliner hole 80 extends axially through the B-bracket 18 between the inboard and outboard walls 70, 72 and axially is aligned with the rotational axis 20.

[0036] Depicted in Figures 4 and 13, the exemplary power disc assembly 12 is generally discshaped and includes a first tooth plate 82 rotatably fixed to the B-bracket 18. In more detail, the first tooth plate 82 is generally ring-shaped and includes a distal wall 84, a proximal wall 86, a center bore 90, and a plurality of output teeth 92. The distal and proximal walls 84, 86 oppose each other, extend radially away from the rotational axis 20. A retaining ring 88 is welded to the outer circumference of the first tooth plate 82. In an exemplary embodiment, the first tooth plate 82 is welded to the B-bracket 18 with the distal wall 84 facing the B-bracket 18. The center bore 90 extends axially through the first tooth plate 82 between the distal and proximal walls 84, 86 and is axially aligned with the rotational axis 20. The plurality of output teeth 92 are spaced apart in a circumferential direction around the center bore 90.

[0037] Depicted in Figures 4 and 5, the exemplary power disc assembly 12 also includes a second tooth plate 94 driveably coupled to the A-bracket 16 and rotatably coupled to the first tooth plate 82. The second tooth plate 94 is generally ring-shaped and includes a distal side 96, a proximal side 98, a rim surface 100, a hub 102, a center aperture 104, and a plurality of input teeth 106. The distal and proximal sides 96, 98 oppose each other, extend radially away from the rotational axis 20, and adjoin the rim surface 100. The proximal side 98 of the second tooth plate 94 is adjacent the proximal wall 86 of the first tooth plate 82. The hub 102 has a generally cylindrical shape projecting from the proximal side 98 and includes a hub wall 108 and a hub ring 110. The hub wall 108 projects axially between the proximal side 98 and an outer edge of the hub ring 1 10 and extends circumferentially around the rotational axis 20. The center aperture 104 is aligned with the rotational axis 20 and extends axially through the second tooth plate 94 between the hub ring 110 and the distal side 96. The plurality of input teeth 106 are spaced circumferentially apart around the center aperture 104. In addition, one of the plurality of output and input teeth 92, 106 is different from the other one of the plurality of output and input teeth 92, 106 by at least one tooth. Further, the plurality of input teeth 106 are configured to meshingly engage with the plurality of output teeth 92 on the first tooth plate 82 to allow rolling movement of the second tooth plate 94 relative to the first tooth plate 82.

[0038] The second tooth plate 94 also includes a plurality of disc bosses 112 projecting axially away from the distal side 96 and defining a plurality of first locking features 112. The plurality of disc bosses 112 includes a first disc boss 112a, a second disc boss 112b, a third disc boss 112c, and a fourth disc boss 112d, which are spaced circumferentially apart around the rotational axis 20. In addition, the plurality of disc bosses 1 12 includes a first latch boss 1 12eand a second latch boss 112f opposing each other with the rotational axis 20 passing therebetween. The first and second latch bosses 112e, 112f define a latching axis 113 extending therebetween. It will be appreciated that any opposing pair of the disc bosses 112 might be selected to be the first and second latch bosses 112e, 112f, with the remaining disc bosses 112 described as the first-fourth bosses 112a-l 12d. Further, it will be appreciated that the first and second latch bosses 112e, 112f might vary in size or shape from the remaining first-fourth disc bosses 1 12a-112d without altering the scope of the present invention. In yet another embodiment, the first and second latch bosses 1 12e, 1 12f might be any opposing pair of the plurality of disc bosses 112.

[0039] The plurality of disc bosses 112 are generally arcuate-shaped and extend in a circumferential direction about the rotational axis 20. Each one of the disc bosses 1 12 includes a lower wall 114 and an outer ledge 116. The lower wall 114 extends circumferentially around the disc boss 112 and projects axially between the distal side 96 and an outer end of the outer ledge 116. In addition, the lower wall 114 includes an inward portion 118 opposing an outward portion 120 and a leading portion 122 opposing a trailing portion 124. It will be appreciated that the quantity, shape, and relative position of the plurality of disc bosses 112 might vary without altering the scope of the present invention. In one exemplary embodiment, the manual override assembly 14 is engaged with the second tooth plate 94 in a predefined rotational alignment relative to the guide aperture 48 in the A-bracket 16, such as the latching axis 113 rotationally aligned with the guide axis 49.

[0040] Depicted in Figures 4, and 13 the exemplary power disc assembly 12 also includes a cam cavity 126 and a cam assembly 128. The cam cavity 126 is a ring-shaped cavity defined radially between the hub wall 108 on the second tooth plate 94 and the center bore 90 on the first tooth plate 82. The cam assembly 128 defines an eccentric which is rotatably mounted between the first tooth plate 82 and the second tooth plate 94 within the cam cavity 126, as is commonly known in the art. Rotation of cam assembly 128 causes the rolling movement of the second tooth plate 94 relative to the first tooth plate 82. The cam assembly 128 includes a cam ring (not shown), wedge(s) (not shown), a wedge spring (not shown), and a coverplate 130, as is commonly known in the art. The components of the cam assembly 128 are not illustrated for simplicity. An exemplary known cam assembly is described in U.S. Patent 5,871,414, the disclosure of which is incorporated by reference herein. Depicted in Figure 13, the cam assembly 128 extends axially through the recliner hole 80 in the B-bracket 18.

[0041] Depicted in Figures 4 and 13, the cam assembly 128 also includes a drive hub 132 which is fixedly coupled to the cover plate 130, rotatably fixed to the drive shaft 24, and rotatably coupled to the center aperture 104 of the second tooth plate 94. The drive hub 132 has a generally cylindrical shape and includes an exterior surface 134, a cam end 136, a lever end 138, a splined hole 140, an internal spline 141, and a retainer groove 142. The exterior surface 134 of the drive hub 132 extends in a circumferential direction about the rotational axis 20 and extends axially between the cam end 136 and the lever end 138. The cam end 136 is fixedly coupled to the cover plate 130. In addition, the drive hub 132 extends axially through the center aperture 104 in the second tooth plate 94. The splined hole 140 extends axially through the drive hub 132 between the cam end 136 and the lever end 138 and is aligned with the rotational axis 20 of the power disc assembly 12. The internal spline 141 extends axially along the inner diameter of the splined hole 140, as is commonly known in the art. The drive shaft 24 extends axially through the splined hole 140 in the drive hub 132 with the spline feature 32 matingly engaged with the internal spline 141. Further, the retainer groove 142 extends in a circumferential direction along the exterior surface 134 of the drive hub 132. The power disc assembly 12 also includes a cam retainer 144 having a ring-shape with a retainer bore 146 extending axially therethrough. The cam retainer 144 is inserted into the retainer groove 142 in the drive hub 132 to retain the input tooth plate 94 spaced axially between the cam retainer 144 and the output tooth plate 82 along the drive hub 132.

[0042] Depicted in Figures 3, 6-9, and 12-15 the manual override assembly 14 provides a manual override feature which allows an occupant to manually rotate one of the A-bracket 16 and the B-bracket 18 relative to the other one of the A-bracket 16 and the B-bracket 18. The manual override assembly 14 allows for an emergency release of the power disc assembly 12 in addition to allowing the occupant to rapidly adjust the rotational position of one of the A- bracket 16 and the B-bracket 18. The manual override assembly 14 includes a locking wedge retainer 148 which is fixedly coupled to the A-bracket 16. The locking wedge retainer 148 is disc-shaped and includes a retainer wall 150, a bracket side 152, a lever side 154, and a slide aperture 156. The retainer wall 150 extends in a circumferential direction and extends axially between the bracket side 152 and the opposing lever side 154. The slide aperture 156 is sized and shaped similarly to the guide aperture 48 in the A-bracket 16. In more detail, the slide aperture 156 has a generally bow-tie shape extending axially between the bracket side 152 and the lever side 154. In an exemplary embodiment, the locking wedge retainer 148 is welded to the A-bracket 16 with the bracket side 152 facing the inboard surface 36 of the A-bracket 16.In addition, the slide aperture 156 includes a forward arch 158, a rearward arch 160, an upper arch 162, a lower arch 164, a front portion 166, a rear portion 168, a forward portion 170, a rearward portion 172, a top slot 174, and a bottom slot 176. The forward and rearward arches 158, 160 extend circumferentially between a lower end of the adjacent front and rear portions 166, 168 and an upper end of the adjacent forward and rearward portions 170, 172, respectively. The top slot 174 is bounded by the upper arch 162, the front portion 166, and the rear portion 168. The bottom slot 176 bounded by the lower arch 164, the forward portion 170, and the rearward portion 172. It will be appreciated that the slide aperture 156 along with the top and bottom slots 174, 176 might vary in shape without altering the scope of the present invention. As assembled, the slide aperture 156 and the guide aperture 48 are axially aligned with the rotational axis 20 with the top and bottom slots 174, 176 rotationally aligned with the upper and lower slots 66, 68, respectively.

[0043] Depicted in Figures 3, 7, and 12-15, the manual override assembly 14 also includes a locking wedge 178 rotatably fixed to the slide aperture 156 in the locking wedge retainer 148 and to the guide aperture 48 in the A-bracket 16. The locking wedge 178 is slidable axially in the lateral direction along the slide aperture 156 and along the guide aperture 48 between a locked position 180 (Figures 12 and 13) and an unlocked position 182 (Figures 14 and 15). In the locked position 180, the locking wedge 178 is rotatably locked to the second tooth plate 94. In contrast, the locking wedge 178 is rotatably decoupled from the second tooth plate 94 in the unlocked position 182. Depicted in Figures 3 and 7, the locking wedge 178 is disc -shaped and includes a rim wall 184, a stop surface 186, a base surface 188, an outer surface 190, a face wall 192, a wedge boss 194, a ring wall 196, a base ring 198, and a central bore 200. The rim wall 184 extends in a circumferential direction and axially between the stop surface 186 and the base surface 188. The outer surface 190 projects axially between the stop surface 186 and the face wall 192 and defines an outer perimeter of the wedge boss 194. The ring wall 196 extends in a circumferential direction and axially between the base surface 188 and the base ring 198. The central bore 200 is aligned with the rotational axis 20 and extends axially between the face wall 192 and the base ring 198. The outer surface 190 of the locking wedge 178 includes a top segment 202, a bottom segment 204, a front segment 206, and a rear segment 208. The top and bottom segments 202, 204 are configured to slidably couple with the upper and lower arches 162, 164 on the slide aperture 156 in the locking wedge retainer 148 and the upper and lower segments 54, 56 in the guide aperture 48 of the A-bracket 16, respectively. The front and rear segments 206, 208 are configured to slidably couple with the forward andrearward arches 158, 160 on the slide aperture 156 and the forward and rearward segments 50, 52 in the guide aperture 48, respectively.

[0044] Depicted in Figure 7, the outer surface 190 also includes a plurality of locking slots 210, which matingly engage and releasably couple with a respective one of the plurality of bosses 112 on the second tooth plate 94. The plurality of locking slots 210 includes a first locking slot 210a, a second locking slot 210b, a third locking slot 210c. and a fourth locking slot 210d. In one exemplary embodiment, the first through fourth locking slots 210a-210d matingly engage and releasably couple with the first through fourth disc bosses 112a-112d, respectively. Each locking slot 210a-210d includes a leading segment 212. a trailing segment 214, and a slot wall 216. Each locking slot 210a-210d also includes a radial opening 218 and a face opening 220. The radial opening 218 is defined between an outer end of one of the leading segments 212 and an outer end of the adjacent trailing segment 214. The face opening 220 is formed in the face wall 192 and bounded by the leading segment 212, the slot wall 216, and the trailing segment 214. The outer surface 190 of the locking wedge 178 also includes a front leg 222, a rear leg 224, and an upper boss 225. The front leg 222, the top segment 202, and the rear leg 224 define the upper boss 225, which is slidably coupled to the top slot 174 in the locking wedge retainer 148 and the upper slot 66 in the A-bracket 16. The front and rear legs 222, 224 are slidably coupled with the front and rear portions 166, 168 in the slide aperture 156 and the front and rear walls 58. 60 in the guide aperture 48, respectively. The outer surface 190 of the locking wedge 178 also includes a forward leg 227, a rearward leg 229, and a lower boss 232. The forward leg 227, the bottom segment 204, and the rearward leg 229 define the lower boss 232, which is slidably coupled to the bottom slot 176 in the locking wedge retainer 148 and the lower slot 68 in the A-bracket 16. The forward and rearward legs 227, 229 are slidably coupled with the forward and rearward portions 170, 172 in the slide aperture 156 and the forward and rearward walls 62, 64 in the guide aperture 48, respectively.

[0045] Depicted in Figure 7, the locking wedge 178 also includes a first locking recess 234 and a second locking recess 236. The first and second locking recesses 234, 236 define a plurality of second locking features 234, 236. Referring to Figures 12 and 13, the locking recesses 234, 236 in the locking wedge 178 are configured to matingly engage and releasably couple with a respective one of the plurality of disc bosses 112 on the second tooth plate 94. In one exemplary embodiment, the locking recesses 234. 236 matingly engage and releasably couple with the first and second latch bosses 1 12e, 1 12f, respectively. Each locking recess 234,236 includes a recess opening 238, an inward wall 240, an outward wall 242, a leading wall 244, a trailing wall 246, and a recess bottom 248. The recess openings 238 are formed in the face wall 192 of the upper and lower bosses 225, 232, respectively. It will be appreciated that the number, shape, and relative position of the locking recesses 234, 236 and the plurality of locking slots 210a-210d might vary without altering the scope of the present invention.

[0046] Depicted in Figure 7. the locking wedge 178 also includes an upper bore 250, a lower bore 252, and a locking cam 254. The locking cam 254 extends radially between a lower end of the upper bore 250 and an upper end of the lower bore 252. The locking cam 254 includes an unlock segment 256, a stop segment 258, a lock segment 260. and a ramp segment 262 forming a first repeating cam profile arranged around the circumference of the central bore 200. In the embodiment shown in Figure 7, the locking cam 254 includes three unlock segments 256 and three lock segments 260 spaced around the central bore 200 in an alternating arrangement. It will be appreciated that the number of unlock and lock segments 256, 260 might vary without altering the scope of the present invention. The unlock segments 256 are spaced axially apart from the lock segments 260. Each stop segment 258 extends axially between an adjacent unlock segment 256 and an adjacent lock segment 260. Each ramp segment 262 is an inclined ramp which extends between an adjacent lock segment 260 and an adjacent unlock segment 256.

[0047] Depicted in Figures 8 and 12-15, the manual override assembly 14 also includes a retractor bushing 264 having a freely rotating radial engagement with the drive hub 132 and which is driveably coupled to the locking wedge 178. The retractor bushing 264 is rotatable about the drive hub 132 between a home position 266 with the locking wedge 178 in the locked position 180 (Figures 12 and 13) and a release position 268 with the locking wedge 178 in the unlocked position 182 (Figure 13 and 14). The retractor bushing 264 has a generally cylindrical shape and includes a bushing aperture 270, a first end 272, a second end 274, an outer wall 276, a bushing cam 278, a bushing wall 280. and a screw thread 282. The bushing aperture 270 extends axially through the retractor bushing 264 aligned with the rotational axis 20 and between the first and second ends 272, 274. The bushing cam 278 extends radially between an upper end of the outer wall 276 and a low er end of the bushing wall 280. The screw thread 282 extends in a circumferential direction between the upper end of the bushing wall 280 and the second end 274, as is commonly known in the art. The bushing cam 278 is a cam profile which includes a high segment 284, a stop wall 286, a low segment 288, and an inclined segment 290forming a second repeating cam profile arranged around the outer circumference of the retractor bushing 264. In the embodiment shown in Figure 8, the bushing cam 278 includes three high segments 284 and three low segments 288 spaced around the bushing wall 280 in an alternating arrangement. It will be appreciated that the quantity of high and low segments 284, 288 might vary' without altering the scope of the present invention. The low segments 288 are spaced axially apart from the high segments 284. Each stop wall 286 extends axially between an adjacent high segment 284 and an adjacent low segment 288. Each inclined segment 290 is an inclined ramp which extends between an adjacent low segment 288 and an adjacent high segment 284.

[0048] Referring to Figures 12-15. the retractor bushing 264 extends axially through the central bore 200 in the locking wedge 178 with the bushing wall 280 having a freely rotating radial engagement with the lower bore 252. Depicted in Figure 13, the bushing cam 278 matingly engages with the locking cam 254 while the locking wedge 178 is in the locked position 180 and the retractor bushing 264 is in the home position 266. The bushing cam 278 causes the locking wedge 178 to translate or move between the locked position 180 and the unlocked position 182 in response to rotation of the retractor bushing 264 about the rotational axis 20 between the home position 266 and the release position 268.

[0049] Depicted in Figure 8. the retractor bushing 264 also includes a first wall 292. a second wall 294, a first ledge 296, and a second ledge 297. The first and second walls 292, 294 extend axially from the second end 274 forming flat portions in the screw thread 282 which are laterally offset with the rotational axis 20 passing therebetween. Each of the first and second walls 292, 294 terminate at a respective one of the first and second ledges 296, 297, which in turn extend radially outward and adjoin the screw thread 282.

[0050] Depicted in Figures 3 and 13, the manual override assembly 14 also includes a first locking spring 298 and a second locking spring 300, which apply a biasing force (arrow 301) in the lateral direction onto the locking wedge 178. The first and second locking springs 298, 300 are installed into the manual override assembly 14 in a preloaded condition to ensure that the locking wedge 178 remains in the locked position 180. The first and second locking springs 298, 300 are conically-shaped disc springs which include a spring rim 302, a lower side 304, an upper side 306. and a spring bore 308. The spring rim 302 extends in a circumferential direction and axially between the lower and upper sides 304, 306. The spring bore 308 extends axially between the lower and upper sides 304, 306 aligned with the rotational axis 20. Depictedin Figure 12, the spring bore 308 has an inner diameter larger than an outer diameter of the ring wall 196 on the locking wedge 178. In addition, the first and second locking springs 298, 300 are stacked in series with the lower sides 304 of the locking springs 298, 300 facing each other, as is commonly known in the art. It will be appreciated that the first and second locking springs 298, 300 might vary in quantity, size, and shape without altering the scope of the present invention. Further, the locking springs 298, 300 might be replaced with an alternate spring, such as one or more of a helical spring, a torsion spring, a conical spring, a leaf spring, and the like, without altering the scope of the present invention. Depicted in Figure 13, the first and second locking springs 298, 300 are assembled in a stacked series arrangement w i th the bushing wall 280 and the screw thread 282 of the retractor bushing 264 extending at least partially through the spring bores 308. In addition, the ring wall 196 of the locking wedge 178 extends at least partially through the spring bore 308 of the first locking spring 298.

[0051] Depicted in Figures 3 and 9-11. the manual override assembly 14 also includes arelease lever 310 which is fixedly coupled to the retractor bushing 264 with a keyed interface for rotating the retractor bushing 264 between the home position 266 and the release position 268. Figure 10 shows the release lever 310 in an unactuated position 311 with the retractor bushing 264 in the home position 266. Figure 11 shows the release lever 310 in an actuated position 312 with the retractor bushing 264 rotated to the release position 268. The unactuated position 311 is rotationally spaced apart from the actuated position 312 by angle 313. Depicted in Figure 9, the release lever 310 includes an inner side 314, an outer side 315, a lower end 318, an upper end 320, and a lever hole 326. The lever hole 326 includes an outer portion 332, an inner portion 334, an upper portion 336, and a lower portion 338. The upper and lower portions 336, 338 are planar walls extending between adjacent ends of the outer and inner portions 332, 334. The release lever 310 also includes a cable hole 340 and a spring aperture 342 spaced apart from the lever hole 326. Referring to Figure 13, the release lever 310 is assembled along the retractor bushing 264 adjacent the second locking spring 300 with the upper and lower portions 336, 338 of the lever hole 326 adjacent the first and second walls 292, 294, respectively.

[0052] Depicted in Figures 3, 10, and 11, the manual override assembly 14 also includes a lever return spring 344, which applies a biasing force (arrow 345) on to the release lever 310 biasing the release lever 310 counterclockwise (arrow 346) towards the unactuated position 311. The lever return spring 344 is an extension spring extending between a first hook 348 and a second hook 349. Depicted in Figure 2, the lever return spring 344 is operatively coupledbetween the release lever 310 and the A-bracket 16 with the first hook 348 fixedly coupled to the spring aperture 342 on the release lever 310 and the second hook 349 fixedly coupled to the spring hole 46 on the A-bracket 16. It will be appreciated that the lever return spring 344 might be a helical spring, a torsion spring, a conical spring, an extension spring, and the like as non-limiting examples, without altering the scope of the present invention.

[0053] Depicted in Figures 3 and 13, the manual override assembly 14 also includes a nut 350. which is mechanically coupled to the retractor bushing 264 and retains the release lever 310 rotationally fixed to the retractor bushing 264. The nut 350 has a ring-shape and includes threaded passageway 351 extending axially therethrough, as is commonly known in the art. The threaded passageway 351 on the nut 350 is meshingly engaged with the screw thread 282 on the retractor bushing 264 with the nut 350 positioned axially between the release lever 310 and the second end 274 of the retractor bushing 264. In addition, the nut 350 allows for a torque monitoring check to ensure a desired pre-compression of the first and second locking springs 298, 300.

[0054] Depicted in Figures 3 and 13, the manual override assembly 14 also includes a retaining clip 352, which retains the drive hub 132 along the drive shaft 24. The retaining clip 352 is a C-shaped clip, as is commonly known in the art. The retaining clip 352 is inserted into the clip groove 34 in the drive shaft 24 and spaced axially between the lever end 138 of the drive hub 132 and the inboard end 30 of the drive shaft 24. It will be appreciated that the threaded connection between the screw thread 282 on the retractor bushing 264 and the nut 350 might be replaced by one or more additional retaining clips inserted into associated slots in the retaining bushing 264, without altering the scope of the present invention.

[0055] Depicted in Figures 2, 10, and 11, the manual override assembly 14 also includes a Bowden cable 356 for selectively actuating the release lever 310. The Bowden cable 356 is configured as is commonly known in the art and includes a cable end 358 fixedly coupled to an end fitting 360. The end fitting 360 is fixedly coupled to the cable hole 340 in the release lever 310. In operation, actuating the Bowden cable 356 applies tension (arrow 362) to the Bowden cable 356, which in turn causes the release lever 310 to rotate clockwise (arrow 364) about the drive shaft 24 to the actuated position 312. Releasing the tension (arrow 365) on the Bowden cable 356 allows the lever return spring 344 to rotate the release lever 310 in the counterclockwise direction (arrow7346) to the unactuated position 311. It will be appreciatedthat the Bowden cable 356 might be replaced with a manual release lever, a linkage, or other known actuating means without altering the scope of the present invention.

[0056] The operation of the power recliner assembly 10 having the manual override assembly 14 is described below in reference to Figures 1 and 10-16. The power recliner assembly 10 is shown with the manual override assembly 14 in a locked condition 370 in Figures 10, 12, and13 and in an unlocked condition 372 in Figures 11, 14, and 15. The manual override assembly14 allows for emergency release of the power recliner assembly 10 for occupant egress. In addition, the manual override assembly 14 allows for rapid adjustment of normally power- operated features. The manual override feature 14 is incorporated into a vehicle seat assembly to provide a fold-flat feature for a power seat back recliner in addition to an emergency release function. It will be appreciated that the manual override assembly 14 might be modified to function in any seat application that includes a power disc assembly 12 without altering the scope of the present invention. The manual override assembly 14 is assembled directly in line with the rotational axis 20 of the power disc assembly 12, which reduces the amount of external shielding required to enclose or protect the manual override assembly 14. Further, the manual override assembly 14 is an improvement over other commonly known add-on latching mechanisms since an add-on latch system is not required. The manual override assembly 14 integrates the manual override function into the power recliner assembly 10 and directly in line with the rotational axis 20 of the power disc assembly 12, which reduces the overall diametrical size of the combined assembly, and which in turn may offer a mass reduction in comparison to known add-on release mechanisms.

[0057] Depicted in Figures 1 and 10-16. the A-bracket 16 is pivotable between an upright position (shown as A-bracket 16 and an upright axis 373), a reclined position (shown as A- bracket 16a and a reclined axis 374) and a fold-flat position (shown as A-bracket 16b and a fold-flat axis 376). Further, the power disc assembly 12 is assembled with the first tooth plate 82 fixedly coupled to the B-bracket 18. The second tooth plate 94 is operatively coupled to the A-bracket 16 via the manual override assembly 14. In addition, the plurality of input teeth 106 on the second tooth plate 94 are in meshing engagement with the plurality of output teeth 92 on the first tooth plate 82. The electric motor 22 is fixedly coupled to the A-bracket 16, driveably coupled to the drive shaft 24, and configured to selectively rotate the drive shaft 24 in the clockwise direction (arrow 364) and in the counterclockwise direction (arrow 346). The drive shaft 24 is rotatably fixed to the drive hub 132, which in turn is fixedly coupled to thecam assembly 128. The cam assembly 128 is operatively coupled between the center bore 90 on the first tooth plate 82 and the hub wall 108 on the second tooth plate 94. The cam assembly 128 causes the second tooth plate 94 to rotate about the first tooth plate 82 in response to the rotation of the drive hub 132, as is commonly know n in the art.

[0058] The manual override assembly 14 rotatably fixes the A-bracket 16 to the second tooth plate 94 while the manual override assembly 14 is in the locked condition 370. The A-bracket 16 is freely rotatable about the rotational axis 20 while the manual override assembly 14 is in the unlocked condition 372. The lever return spring 344 biases the release lever 310 in the counterclockwise direction (arrow 345) towards the unactuated position 311. The Bowden cable 356 is fixedly coupled to the release lever 310 for actuating the release lever 310. Further, the release lever 310 is keyed to the retractor bushing 264 such that rotating the release lever 310 causes the retractor bushing 264 to rotate. The retractor bushing 264 is freely rotatable about the drive hub 132 and rotatable between the home position 266 and the release position 268. Further, the bushing cam 278 on the retractor bushing 264 is operatively coupled to the locking cam 254 on the locking wedge 178. The locking wedge 178 is slidably coupled and rotatably fixed to the guide aperture 48 in the A-bracket 16 and to the slide aperture 156 in the locking wedge retainer 148. In addition, the locking wedge 178 is translatable or movable laterally between the locked position 180 and the unlocked position 182. When the manual override assembly 14 is in the locked condition 370. the first and second latch bosses 112e, 1 12f on the second tooth plate 94 are inserted at least partially into the first and second locking recesses 234, 236, respectively, on the locking wedge 178, which in turn rotatably fixes the locking wedge 178 to the second tooth plate 94 and to the A-bracket 16. When the manual override assembly 14 is in the unlocked condition 372, the first and second latch bosses 112e, 112f are axially spaced apart from the first and second locking recesses 234, 236, which in turn rotatably decouples the locking w edge 178 from the A-bracket 16 and the second tooth plate 94. The first and second locking springs 298, 300 are in a preloaded condition and apply a biasing force (arrow 301) onto the locking wedge 178. which biases the locking wedge 178 laterally inward (arrow 382) towards the locked position 180.

[0059] Initially, the manual override assembly 14 is in the locked condition 370 with the A- bracket 16 in the upright position, shown with the guide axis 49 of the guide aperture 48 aligned with the upright axis 373. In addition, the release lever 310 is in the unactuated position 311 and the Bowden cable 356 is in the unactuated condition. The retractor bushing 264 is in thehome position 266. The locking wedge 178 is in the locked position 180 with the latch bosses 112e. 112f matingly engaged with the first and second locking recesses 234, 236, respectively. The A-bracket 16 is rotatably fixed to the second tooth plate 94 of the power disc assembly 12 via the locking wedge 178 since the locking wedge 178 is in the locked position 180.

[0060] To automatically adjust the rotational position of the A-bracket 16 relative to the B- bracket 18. the occupant initiates operation of the electric motor 22, which in turn causes the drive shaft 24 to rotate in one of the counterclockwise and clockwise directions (arrows 346, 364). Next, the rotation of the drive shaft 24 causes the drive hub 132 to rotate, which in turn causes the cam assembly 128 to rotate the second tooth plate 94 about the first tooth plate 82, as is commonly known in the art. The rotation of the second tooth plate 94 causes the A-bracket 16 to rotate relative to the B-bracket 18 while the manual override assembly 14 is in the locked condition 370. In addition, the rotational position of the latching axis 113 relative to the B- bracket 18 will change as the A-bracket 16 is rotated. Depicted in Figure 16, the A-bracket 16 is automatically rotatable rearward towards the rearward position (shown as the A-bracket 16a and the reclined axis 374) and forward toward the fold-flat position (shown as A-bracket 16b and the fold-flat axis 376). Next, the occupant terminates operation of the electric motor 22 when the A-bracket 16 is in a desired position, such as shown by A-bracket 16c and position axis 383. The current position of the A-bracket 16 (i.e., A-bracket 16c) is maintained until the occupant initiates operation of the electric motor 22 again or until the occupant initiates manual rotation of the A-bracket 16.

[0061] The manual adjustment of the A-bracket 16 relative to the B-bracket 18 is described below. Initially, the manual override assembly 14 is in the locked condition 370 with the A- bracket 16 in an initial position 16c (shown as A-bracket 16c and position axis 383 in Figure 16). It will be appreciated that the initial position 16c of the A-bracket 16 might be in any rotational position between the reclined position (shown as A-bracket 16a and the reclined axis 374) and the fold-flat position (shown as A-bracket 16b and the fold-flat axis 376), without altering the scope of the present invention.

[0062] Next, the occupant initiates unlocking of the manual override assembly 14 by actuating the Bowden cable 356. Actuating the Bowden cable 356 applies tension (arrow 362) to the Bowden cable 356, which in turn causes the release lever 310 to rotate in the clockwise direction (arrow 364) about the rotational axis 20 from the unactuated position 311 towards the actuated position 312. The rotation of the release lever 310 also causes the retractor bushing264 to rotate in the clockwise direction (arrow 364) from the home position 266 towards the release position 268. In addition, the lever return spring 344 is elongated as the release lever 310 rotates, which in turn applies a biasing force (arrow 345) onto the release lever 310 and biases the release lever 310 towards the unactuated position 311.

[0063] As the retractor bushing 264 rotates in the clockwise direction (arrow 364) away from the home position 266. the inclined segment 290 on the bushing cam 278 frictionally engages with the adjacent unlock segment 256 on locking cam 254, which in turn causes the locking wedge 178 to slide or translate laterally outward (arrow 384) towards the unlocked position 182 along the guide aperture 48 in the A-bracket 16 and along the slide aperture 156 in the locking wedge retainer 148. Additional rotation of the retractor bushing 264 in the clockwise direction (arrow 364) causes the high segment 284 on the bushing cam 278 to frictionally engage with the adjacent unlock segment 256 on the locking cam 254, which in turn causes the locking wedge 178 to slide or translate laterally outward (arrow' 384) to the unlocked position 182. The lateral outward movement (arrow 384) of the locking wedge 178 further compresses the first and second locking springs 298, 300. In addition, the lateral outward movement (arrow 384) of the locking wedge 178 causes the first and second locking recesses 234, 236 to disengage from the first and second latch bosses 112e, 112f on the second tooth plate 94, which in turn repositions the manual override assembly 14 to the unlocked condition 372. The A- bracket 16 is allowed to freely rotate while the locking recesses 234. 236 are laterally spaced apart from the latch bosses 112e, 112f. The locking wedge 178 continues to be engaged with the A-bracket 16 through the locking wedge retainer 148 while the locking wedge 178 is disengaged from the power disc assembly 12. The freely rotating radial engagement between the retractor bushing 264 and the drive hub 132 in combination with the engagement between the locking wedge 178 and the A-bracket 16 allows rotation of the A-bracket 16 without radial disengagement from the power disc assembly 12. Next, the occupant freely rotates the A- bracket 16 to a desired rotational position, such as the fold-flat position 16b as a non-limiting example, while the manual override assembly 14 is in the unlocked condition 372.

[0064] After the A-bracket 16 is rotated to the desired rotational position (i.e., the fold-flat position 16b), the occupant releases the Bow den cable 356, which in turn releases the tension (arrow 365) in the Bowden cable 356. After tension (arrow 365) is released from the Bowden cable 356, the tension (arrow 345) in the lever return spring 344 biases the release lever 310 and the retractor bushing 264 back towards their design positions (i.e., the unactuated position311 and the home position 266, respectively). In more detail, lever return spring 344 causes the release lever 310 to rotate in the counterclockwise direction (arrow 346) from the actuated position 312 towards the unactuated position 311, which also causes the retractor bushing 264 to rotate from the release position 268 and towards the home position 266.

[0065] As the retractor bushing 264 rotates in the counterclockwise direction (arrow 346), the high segment 284 on the bushing cam 278 of the retractor bushing 264 disengages from the unlock segment 256 on the locking cam 254 and causes the stop wall 286 to rotate past the unlock segment 256 on the locking cam 254. The locking wedge 178 is allowed to move towards the locked position 180 after the high segment 284 disengages from the unlock segment 256. Additional rotation of the retractor bushing 264 in the counterclockwise direction (arrow 346) rotationally aligns the low segment 288 on the bushing cam 278 of the retractor bushing 264 with the unlock segment 256 on the locking cam 254. The compressed first and second locking springs 298, 300 apply a biasing force (arrow 301) onto the locking wedge 178, which causes the locking wedge 178 to slide or translate laterally inward (arrow 382) towards the locked position 180 along the guide aperture 48 and the slide aperture 156, causing the unlock segment 256 on the locking cam 254 to translate towards the low segment 288 on the bushing cam 278. The manual override assembly 14 is retained in the unlocked condition 372 while the A-bracket 16 is spaced apart from the initial released position 16c since the first and second locking recesses 234, 236 are not rotationally aligned with the first and second latch bosses 1 12e, 112f on the second tooth plate 94.

[0066] To relock the manual override assembly 14, the occupant rotates the A-bracket 16 back to the initial released position 16c. which causes the first and second locking recesses 234, 236 to align with the first and second latch bosses 1 12e, 1 12f. After the locking features 112e, 1 12f, 234, 236 of the power disc assembly 12 and the locking wedge 178 align, the biasing force (arrow 301) in the first and second locking springs 298, 300 cause the locking wedge 178 to laterally translate back towards the locked position 180 (arrow 382). Next, the first and second locking recesses 234, 236 in the locking wedge 178 meshingly engage with the adjacent first and second latch bosses 112e, 112f on the second tooth plate 94, which returns the locking wedge 178 to the locked position 180, and returns the manual override assembly 14 to the locked condition 370 with the A-bracket 16 rotatably fixed to the second tooth plate 94.

[0067] A second embodiment of the power recliner assembly 10' is illustrated in Figures 1- 16, where like primed reference numerals represent similar elements as those described above.Only significant differences between the two embodiments are reflected in the Figures and the description below.

[0068] The second embodiment of the power recliner assembly 10' allows the manual override assembly 14' to relock in any one of a plurality of locking positions. In contrast, the first embodiment of the power recliner assembly 10 allows the manual override assembly 14 to relock solely in the initially released position 16c, with the first and second locking recesses 234, 236 aligned with the first and second latch bosses 112e, 112f.

[0069] Depicted in Figure 5, the second tooth plate 94' includes a plurality of bosses 112' projecting axially away from the distal side 96’ and defining a plurality of first locking features 112'. The plurality of bosses 112' are spaced circumferentially around the center aperture 104'. In addition, the plurality of bosses 112' are equally spaced and form pairs of opposing bosses 112'.

[0070] Depicted in Figure 7, the locking wedge 178' includes a plurality of locking slots 210', which matingly engage and releasably couple with a respective one of the plurality of bosses 112' on the second tooth plate 94'. The plurality of locking slots 210' includes a first locking slot 210a', a second locking slot 210b'. a third locking slot 210c'. and a fourth locking slot 210d'. The locking wedge 178' also includes a first locking recess 234' and a second locking recess 236', which matingly engage and releasably couple with a respective one of the plurality of bosses 112' on the second tooth plate 94'.

[0071] The operation ofthe power recliner assembly 10' having the manual override assembly 14' is similar to the embodiment described above. However, the manual override assembly 14' is allowed to relock when the first and second locking recesses 234', 236' align and meshingly engage with any pair of the plurality of bosses 112'. As such, the occupant is allowed to relock the manual override assembly 14' in any one of a plurality’ of radial locking positions.

[0072] A third embodiment of the power recliner assembly 10" is illustrated in Figures 1, 2, 17 and 18, where like double primed reference numerals represent similar elements as those described above. Only significant differences between the embodiments are reflected in the Figures and the description below. The third embodiment of the power recliner assembly 10" includes a power disc assembly 12" and a manual override assembly 14" configured to relock with a single locking position.

[0073] Depicted in Figure 17, the power disc assembly 12" includes a modified second tooth plate 94" having an upper aperture 390 and a lower aperture 392 formed in the distal side 96". The upper and lower apertures 390, 392 define a plurality of first locking features 390, 392. The upper and lower apertures 390, 392 are generally arcuate-shaped, oppose each other, and extend in a circumferential direction about the center aperture 104". The upper and lower apertures 390, 392 include a first curved wall 394, a second curved wall 396, a first radial wall 398, and a second radial wall 400. The first and second radial walls 398, 400 extend in a radial direction between adjacent ends of the first and second curved walls 394, 396.

[0074] Depicted in Figure 18, the manual override assembly 14" includes a modified locking wedge 178" having a top boss 402 and a bottom boss 404 projecting away from the face wall 192". The top and bottom bosses 402, 404 define a plurality of second locking features 402, 404. The top and bottom bosses 402, 404 are keyed locking features with individual profiles which are configured to engage with the upper and lower apertures 390, 392, respectively, on the modified second tooth plate 94" to provide a single-position locking feature. In more detail, the top and bottom bosses 402, 404 are generally arcuate-shaped, extend in a circumferential direction about the center bore 200", and oppose each other. The top and bottom bosses 402, 404 are spaced radially outward of the locking cam 254". Each of the top and bottom bosses 402, 404 includes an outward side 406, an inward side 408, a first radial side 410, and a second radial side 412. The first and second radial sides 410, 412 extend in a radial direction between adjacent ends of outward and inward sides 406, 408. In addition, the locking cam 254" includes an unlock segment 256", a stop segment 258", a lock segment 260", and a ramp segment 262" forming a repeating cam profile arranged around the circumference of the central bore 200". The locking cam 254" functions as described above for causing the modified locking wedge 178" to translate laterally outward and disengage from the modified second tooth plate 94".

[0075] It will be appreciated that the upper and lower apertures 390, 392 on the modified second tooth plate 94" and the top and bottom bosses 402, 404 on the modified locking wedge 178" might be swapped without altering the scope of the present invention. For example, the upper and lower apertures 390, 392 might be formed in the modified locking wedge 178" with the top and bottom bosses 402, 404 formed in the modified second tooth plate 94". It will be appreciated that one of the plurality of first locking features 390, 392 and the plurality of second locking features 402, 404 includes boss-shaped features and an other one of the plurality of first locking features 390, 392 and the plurality of second locking features 402, 404 includesslot-shaped features. It will also be appreciated that the modified second tooth plate 94" might include a first locking feature 390. 392 and the modified locking wedge 178" might include a second locking feature 402, 404 which is keyed to engage with the first locking feature 390, 392. Thus, the amount of locking features might vary without altering the scope of the present invention.

[0076] The operation of the power recliner assembly 10" having the manual override assembly 14" is similar to the first embodiment described above. The manual override assembly 14” is allowed to relock when the top and bottom bosses 402, 404 align and meshingly engage with the upper and lower apertures 390, 392, respectively. As such, the occupant is allowed to relock the manual override assembly 14" in a single radial locking position corresponding to the initially released location.

[0077] As discussed above, the power recliner assembly 10, 10', 10" of the present invention includes an A-bracket 16 having a guide aperture 48 extending therethrough, a B-bracket 18, a power disc assembly 12, 12', 12", and a manual override assembly 14, 14', 14". The power disc assembly 12, 12', 12" includes a first tooth plate 82 rotatably fixed to the B-bracket 18 and a second tooth plate 94, 94', 94" rotatably coupled to the first tooth plate 82. The second tooth plate 94, 94', 94" includes a center aperture 104, 104', 104" extending axially therethrough, a first locking feature 112. 112' projecting away from the first tooth plate 82, and a cam assembly 128 rotatably mounted between the first tooth plate 82 and the second tooth plate 94. The cam assembly 128 includes a drive hub 132 which extends axially through the center aperture 104, 104', 104" and through the guide aperture 48 and defines a rotational axis 20. The power recliner assembly 10, 10', 10" also includes a drive shaft 24 driveably coupled to the drive hub 132. In addition, the manual override assembly 14, 14', 14" includes a locking w?edge 178, 178', 178" having a wedge boss 194 slidably coupled to the guide aperture 48, a central bore 200, 200" extending axially therethrough, and a second locking feature 234, 236, 234", 236" formed in the wedge boss 194. The drive hub 132 extends at least partially through the central bore 200, 200". The locking wedge 178, 178', 178" is movable along the guide aperture 48 between a locked position 180 and an unlocked position 182 spaced apart from the locked position 180. In addition, the first locking feature 112, 112' is frictionally engaged w ith the second locking feature 234, 236, 234". 236" while the locking wedge 178, 178', 178" is in the locked position 180, which rotatably fixes the A-bracket 16 to the second tooth plate 94, 94'. 94". Further, the first locking feature 112, 1 12' is spaced apart from the second locking feature 234, 236, 234",236" while the locking wedge 178, 178', 178" is in the unlocked position 182, which allows the A-bracket 16 to rotate relative to the second tooth plate 94, 94'. 94''. The manual override assembly 14, 14', 14" provides a manual latch for releasing the power disc assembly 12, 12', 12", and is aligned with the rotational axis 20 of the power disc assembly 12, 12', 12". In addition, the manual override assembly 14, 14', 14" is integrally assembled with the power recliner assembly 10, 10', 10" and provides a manual unlatch function without requiring an external manual latch. Further, the integrated manual override assembly 14, 14'. 14" which is aligned with the rotational axis 20 of the power disc assembly 12, 12', 12" has an advantage of reducing an overall radial dimension of the combined power disc assembly 12, 12', 12" and the manual override assembly 14, 14', 14", which in turn may reduce the amount of shielding required to protect these components and may further result in an overall weight reduction.

[0078] The invention has been described in an illustrative manner, and it is to be understood that the terminology', which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:

1. A power recliner assembly for a seat assembly for use in an automotive vehicle, the power recliner assembly comprising: an A-bracket including a guide aperture extending therethrough; a B-bracket; a power disc assembly compnsing a first tooth plate rotatably fixed to the B-bracket. a second tooth plate rotatably coupled to the first tooth plate and having a first locking feature, a center aperture extending axially therethrough, and a cam assembly rotatably mounted between the first tooth plate and the second tooth plate: a drive hub extending axially through the center aperture and through the guide aperture, the drive hub defining a rotational axis; a drive shaft driveably coupled to the drive hub; and a manual override assembly comprising a locking wedge, the locking wedge including a wedge boss slidably coupled to the guide aperture, a central bore extending axially therethrough, and a second locking feature formed in the wedge boss, wherein the drive hub extends at least partially through the central bore; wherein the locking wedge is movable along the guide aperture between a locked position and an unlocked position spaced apart from the locked position; wherein the first locking feature is frictionally engaged with the second locking feature while the locking wedge is in the locked position, which prevents rotation of the A-bracket relative to the B-bracket; and wherein the first locking feature is spaced apart from the second locking feature while the locking wedge is in the unlocked position, which allows the A-bracket to rotate relative to the B-bracket.

2. The power recliner assembly as set forth in claim 1, wherein: the first tooth plate further includes a plurality of output teeth spaced circumferentially apart and around the first tooth plate; the second tooth plate includes a plurality of input teeth spaced circumferentially apart and around the second tooth plate and meshingly engaged with the plurality of output teeth on the first tooth plate, wherein the plurality of output teeth and the plurality’ of input teeth are different by at least one tooth; andthe cam assembly defines an eccentric rotatably mounted between the first tooth plate and the second tooth plate.

3. The power recliner assembly as set forth in one of claim 1 or claim 2, further comprising: a retractor bushing including a bushing wall extending in a circumferential direction, a bushing aperture extending axially therethrough, and a bushing cam extending circumferentially along the bushing wall; and a locking cam extending circumferentially along the central bore of the locking wedge; wherein the drive hub extends at least partially through the bushing aperture with the bushing aperture in a freely rotating radial engagement with the drive hub, the bushing wall extends at least partially through the central bore in the locking wedge with the bushing cam driveably coupled to the locking cam, and the retractor bushing rotatable about the drive hub between a home position and a release position rotationally spaced apart from the home position; and wherein the bushing cam causes the locking wedge to translate along the guide aperture towards the unlocked position as the retractor bushing rotates from the home position towards the release position.

4. The power recliner assembly as set forth in claim 3, wherein: the locking cam further comprises an unlock segment, a stop segment, a lock segment, and a ramp segment forming a first repeating cam profile arranged circumferentially around the central bore, wherein the unlock segment is spaced axially apart from the lock segment; the bushing cam further comprises a high segment, a stop wall, a low segment, and an inclined segment forming a second repeating cam profile arranged around an outer circumference of the retractor bushing, wherein the high segment is axially spaced apart from the low segment; wherein rotating the retractor bushing causes the high segment to frictionally engage with an adjacent unlock segment which causes the locking wedge to move away from the first locking feature; and wherein the locking wedge is allowed to move towards the first locking feature while the high segment is disengaged from the adjacent unlock segment.

5. The power recliner assembly as set forth in any one of claim 1 through 4, further comprising: a locking wedge retainer including a slide aperture extending therethrough and fixedly coupled to the A-bracket with the slide aperture aligned with the guide aperture;wherein the wedge boss is slidably coupled to the slide aperture and movable along the slide aperture between the locked position and the unlocked position.

6. The power recliner assembly as set forth in claim 5, wherein: the guide aperture includes an upper slot spaced apart from a lower slot; the slide aperture includes a top slot spaced apart from a bottom slot; and the wedge boss includes an upper boss spaced apart from a lower boss, the upper boss slidably coupled to the upper slot and the top slot, and the lower boss slidably coupled to the lower slot and the bottom slot.

7. The power recliner assembly as set forth in any one of claim 1 through 6, further comprising: an electric motor driveably coupled to the drive shaft.

8. The power recliner assembly as set forth in one of claim 3 or claim 4, further comprising: a release lever fixedly coupled to the retractor bushing and rotatable between an unactuated position and an actuated position; a locking spring biasing the locking wedge towards the locked position; and a lever return spring biasing the release lever towards the unactuated position.

9. The power recliner assembly as set forth in any one of claim 1 through 7, wherein: one of the first locking feature and the second locking feature is a boss; and the other one of the first locking feature and the second locking feature is a locking recess.

10. The power recliner assembly as set forth in any one of claim 1 through 7, wherein: the first locking feature comprises a plurality7of disc bosses which are spaced circumferentially apart; the second locking feature comprises a first locking recess and a second locking recess spaced circumferentially apart; and the locking wedge further comprises a plurality7of locking slots spaced circumferentially apart about the central bore; wherein each one of the plurality of disc bosses engages with one of the first locking recess, the second locking recess, or one of the plurality of locking slots thereby defining the locking wedge in the locked position.

11. The power recliner assembly as set forth in any one of claim 1 through 7. wherein:the first locking feature comprises a plurality of disc bosses which are spaced circumferentially apart and further comprises a first latch boss spaced circumferentially apart from a second latch boss; the second locking feature comprises a first locking recess and a second locking recess spaced circumferentially apart; and the locking wedge further comprises a plurality of locking slots spaced circumferentially apart about the central bore; wherein each one of the plurality of disc bosses engages with one of the plurality of locking slots, the first latch boss engages with the first locking recess, and the second latch boss engages with the second locking recess thereby defining the locking wedge in the locked position.

12. A power recliner assembly for a seat assembly for use in an automotive vehicle, the power recliner assembly comprising: an A-bracket including a guide aperture extending therethrough; a B-bracket; a power disc assembly including a first tooth plate rotatably fixed to the B-bracket, a second tooth plate rotatably coupled to the first tooth plate and having a first locking feature, a center aperture extending therethrough, and a drive hub extending though the center aperture; and a manual override assembly including a locking wedge having a second locking feature and a central bore extending therethrough, the locking wedge is slidably coupled to the guide aperture, and the drive hub extends at least partially through the central bore; wherein the locking wedge is movable along the guide aperture between a locked position and an unlocked position spaced apart from the locked position; wherein the first locking feature is frictionally engaged with the second locking feature while the locking wedge is in the locked position, which prevents rotation of the A-bracket relative to the B-bracket; and wherein the first locking feature is spaced apart from the second locking feature while the locking wedge is in the unlocked position, which allows the A-bracket to rotate relative to the B-bracket.

13. The power recliner assembly as set forth in claim 12, wherein: the drive hub defines a rotational axis of the power disc assembly; andthe locking wedge is axially aligned with the rotational axis and movable in an axial direction between the locked position and the unlocked position, wherein the locking wedge is rotatably fixed to the A-bracket.

14. The power recliner assembly as set forth in one of claim 12 or claim 13, further comprising: a locking cam extending circumferentially along the central bore of the locking wedge and including an unlock segment, a stop segment, a lock segment, and a ramp segment forming a first repeating cam profile arranged circumferentially around the central bore, wherein the unlock segment is spaced axially apart from the lock segment; and a retractor bushing spaced radially between the drive hub and the locking wedge and including a bushing cam which includes a high segment, a stop wall, a low segment, and an inclined segment forming a second repeating cam profile arranged around an outer circumference of the retractor bushing, wherein the high segment is axially spaced apart from the low segment; wherein rotating the retractor bushing causes the high segment to frictionally engage with an adjacent unlock segment which causes the locking wedge to move axially away from the first locking feature; and wherein the locking wedge is allowed to move axially towards the first locking feature while the high segment is disengaged from the adjacent unlock segment.

15. The power recliner assembly as set forth in claim 14, further comprising: a release lever fixedly coupled to the retractor bushing and rotatable between an unactuated position and an actuated position; a locking spring biasing the locking wedge towards the locked position: and a lever return spring biasing the release lever towards the unactuated position.

Images