AU2011211400B2 - Child safety seat reinforcement - Google Patents

Abstract

This invention relates to a child restraint apparatus for restraining a child within a vehicle, the child restraint apparatus comprising a form giving structure and a lamina of material secured to a surface of 5 at least a portion of the structure so as to thereby reinforce at least said portion. An associated lamina of material for securement to a surface of a child restraint apparatus is also disclosed. co) ' C% 00

Description

Regulation 3.2 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: Britax Childcare Pty Ltd Actual Inventors: Mike Lumley Wieslaw Maciejczyk Address for Service: C/- MADDERNS, GPO Box 2752, Adelaide, South Australia, Australia Invention title: CHILD SAFETY SEAT REINFORCEMENT The following statement is a full description of this invention, including the best method of performing it known to us.

TITLE CHILD SAFETY SEAT REINFORCEMENT 5 FIELD OF THE INVENTION This invention relates to means and methods for improving juvenile seating products by reinforcing them. PRIORITY 0 This patent application claims priority from: Australian Provisional Patent Application 2010903615, titled "CHILD SAFETY SEAT REINFORCEMENT", and filed on 12 August 2010. 5 The entire content of this application is hereby incorporated by reference. BACKGROUND OF THE INVENTION Child safety seats generally comprise a form giving shell comprising a seat portion, and, optionally, a .0 backrest portion, and may be of the booster seat variety, or the safety seat may be secured with respect to the vehicle by the seat belts and have an independent harness which secures the infant with respect to the safety seat. Polymeric foam materials (hereinafter foam) such as EPS, EPP and/or other cellular foam or bead 25 structures are commonly used to provide the form giving seat shell that forms a key part of a seat assembly. This form giving seat shell is generally further covered with additional padding and a dress cover. Whilst not especially fragile, these foam shells are prone to damage by accidental breakage in 30 everyday use. In addition, the shell, be this foam or otherwise, can be broken in a vehicle accident, although usually not during the main frontal phase of the accident, where the occupant is thrown forward, but in the rebound phase, where the occupant rebounds back in to the seat. This rebounding effect can break a foam shell due to the stored energy in the seat belt and seat cushion. The foam breaks by breaking the bond between the foam beads, or by causing the foam beads to break. 35 2 It is preferred however that the form giving shell of a child safety seat, be this made of foam or otherwise, does not break, so that the occupant is restrained in the best possible manner throughout the crash duration. 5 It is against this background and the problems and difficulties associated therewith that the present invention has been developed. Certain objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and 0 example, an embodiment of the present invention is disclosed. SUMMARY OF THE INVENTION In one aspect, the invention the may be said to reside in a child restraint apparatus for restraining a 5 child within a vehicle, the child restraint apparatus comprising a seat shell having at least a portion with a pair of substantially oppositely directed surfaces or sides, and one or more lamina contiguously secured to both of these substantially oppositely directed surfaces or sides of the portion so as to thereby reinforce at least said portion of the seat shell. '0 In one form, the lamina is a sheet or strip of flexible material. In one form, the lamina is secured to the seat shell with an adhesive. In one form, the lamina is shaped and/or adapted to provide optimised reinforcement for a specific 25 surface or portion of the seat shell. In one form, the seat shell comprises a portion having a pair of substantially oppositely directed surfaces or sides, and said portion is reinforced by lamina secured to both of these substantially oppositely directed surfaces or sides. 30 In one form, the pair of substantially oppositely directed surfaces or sides are reinforced by a single lamina. In one form, the pair of substantially oppositely directed surfaces or sides are reinforced by way of one 35 lamina secured to one surface or side, and a second lamina secured to the oppositely directed surface or side.

In one form, the pair of substantially oppositely directed surfaces or sides are an inner surface or side and an outer surface or side of the portion of the form giving structure. 5 In one form, the or each lamina extends across, around or between at least two adjoining surfaces or portions of the form giving structure. In one form, wherein the two adjoining surfaces or portions of the seat shell reinforced are at least part of one or more of: 0 a base and a backrest; and/or a backrest and a sidewing; and/or a base and a bolster; and/or a headrest and a sidewing of a headrest. 5 In one form, all or part of the form giving structure is made of a foam material. In one form, the or each lamina is a thin sheet of strong but flexible polymer or plastic film. In one form, at least portions of one side of the or each lamina of reinforcing material are covered with .0 adhesive. In one form, an entirety of one side of the or each lamina of reinforcing material is covered with adhesive. 25 In one form, the adhesive covered side of the or each lamina is further covered by a peel-off backing layer. In one form, this peel-off backing layer is removed prior to the application of the or each lamina of reinforcing material to the form giving structure. 30 In one form, a lamina forming liquid is painted or sprayed onto all or part of the form giving structure in liquid form, and this then provides its reinforcing properties when it dries or cures. In one form, at least part of the form giving structure is dipped into a lamina forming liquid, which 35 will provide its reinforcing properties when it dries or cures. 4 In a further aspect, the invention the may be said to reside in a the child restraint apparatus comprising a form giving structure having a portion with a pair of substantially oppositely directed surfaces or sides, and one or more lamina contiguously secured to both of these substantially oppositely directed surfaces or sides so as to thereby reinforce at least said portion, 5 In a further aspect, the invention the may be said to reside in a child safety seat assembly comprising a form giving seat shell of polymeric foam material, and a lamina which is contiguously secured to at least a portion of a surface of the seat shell so as to cover and reinforce at least said portion. 0 In a further aspect, the invention the may be said to reside in a lamina of material for securement to a surface of at least a part of a portion of a child restraint apparatus for restraining a child within a vehicle, so as to thereby reinforce at least said portion. In a further aspect, the invention the may be said to reside in a shaped lamina for securement to a foam 5 surface portion of a child safety seat so as to thereby reinforce the foam portion. In one form, the lamina also protects the portion covered thereby. In one form, in an alternative, the lamina comprises a composite material. In one form, the lamina is .0 reinforced such as with fibre reinforcing for instance. In one form the lamina comprises thin layers, sheets or lamina. It can be seen then that the lamina may be a sheet of plastic, rubber, PVC or any other elastomer or plastic material with the possible inclusion of laminations and/or woven fabric or strands of glass 25 fibre, cotton, wool or polymer fibre for instance. In one form, if despite being reinforced by a lamina, the seat shell is broken, then the broken piece will not separate from the remainder of the seat shell, but the lamina will hold this broken portion in its original position with respect to the remainder of the seat shell. 30 DESCRIPTION OF THE DRAWINGS For a better understanding of this invention it will now be described with respect to one or more exemplary embodiments which shall be described herein with the assistance of drawings, wherein: 35 Figure 1 is a front perspective view of a child safety seat assembly according to a first exemplary embodiment; Figure 2 is a rear perspective view of the child safety seat assembly illustrated in Figure 1; Figure 3 is a front perspective view of a child safety seat assembly according to a second exemplary 5 embodiment; Figure 4 is a rear perspective view of the child safety seat assembly illustrated in Figure 3; Figure 5 is a front perspective view of a child safety seat assembly according to a third exemplary 0 embodiment; Figure 6 is a rear perspective view of the child safety seat assembly illustrated in Figure 5; Figure 7 is a front perspective view of a child safety seat assembly according to a fourth exemplary 5 embodiment; Figure 8 is a rear perspective view of the child safety seat assembly illustrated in Figure 7; Figure 9 is a front perspective view of a child safety seat assembly according to a fifth exemplary .0 embodiment; Figure 10 is a rear perspective view of the child safety seat assembly illustrated in Figure 9; Figure I I is a front perspective view of a child safety seat assembly according to a sixth exemplary 25 embodiment; Figure 12 is a rear perspective view of the child safety seat assembly illustrated in Figure 11; Figure 13 is a front perspective view of a child safety seat assembly according to a seventh exemplary 30 embodiment; Figure 14 is a rear perspective view of the child safety seat assembly illustrated in Figure 13; Figure 15 is a front perspective view of a child safety seat assembly according to an eighth exemplary 35 embodiment; Figure 16 is a rear perspective view of the child safety seat assembly illustrated in Figure 15; 6 Figure 17 is a front perspective view of a child safety seat assembly according to a ninth exemplary embodiment; 5 Figure 18 is a rear perspective view of the child safety seat assembly illustrated in Figure 17; Figure 19 is a front perspective view of a child safety seat assembly according to a tenth exemplary embodiment; 0 Figure 20 is a rear perspective view of the child safety seat assembly illustrated in Figure 19; Figure 21 is a front perspective view of a child safety seat assembly according to an eleventh exemplary embodiment; 5 Figure 22 is a rear perspective view of the child safety seat assembly illustrated in Figure 21; and Figure 23 is a plan view of a blank for the reinforcing sheet illustrated in the assembly of Figures 21 and 22. 0 In the following description, like reference characters designate like or corresponding parts throughout the several views of the drawings. DESCRIPTION OF THE PREFERRED EMBODIMENT 25 Referring now to Figures 1 and 2, where there is illustrated a child safety seat assembly I according to a first exemplary embodiment, the assembly comprising a form giving seat shell 2 of polymeric foam such as closed-cell extruded polystyrene foam. It should be understood however, that the invention is not limited to use with seat shells of polymeric foam, but could be used with seat shells made from any suitable material, including injection or blow moulded plastic materials. Similarly, the invention need 30 not be limited to a seat shell, but is instead applicable to a form giving shell of a capsule or infant carrier for instance. The seat shell 2 integrally defines a base 4 (i.e. the seat portion), a backrest 6, a pair of sidewings 8 extending forward from the edges of the backrest 6, and a pair of bolsters 10 extending upward from 35 the edges of the base 4. 7 Extending up a front side of the backrest 6, over the top edge of the backrest 6 and partway down the rear side of the back rest 6, so as to cover a significant portion of each, is a rectangular reinforcing lamina or sheet 20. 5 The reinforcing sheet 20 is a sheet or lamina of flexible but strong polymeric film, which is entirely covered on one side by an adhesive that is suitable for contiguously securing this reinforcing sheet to a surface of the closed-cell extruded polystyrene foam of the seat shell 2 by laying over or atop of this surface so as to cover it. 0 In this way, the reinforcing sheet or lamina 20 provides reinforcement to both the backrest 6 of the seat shell 2 and along the top edge of the backrest 2. Reinforcing sheet 20 also extends around the seatbelt apertures 12 that pass through the backrest 2 of the seat shell 2. The foam of seat shell 2 is particularly vulnerable to break at points such as around these apertures 12 and along the top edge of the backrest 6. 5 Referring now to Figures 3 and 4, where there is illustrated a child safety seat assembly 30 according to a second exemplary embodiment, the assembly comprising a form giving seat shell 2 of polymeric foam of the type discussed above. .0 There is a rectangular reinforcing sheet 40 of the type described above, adhered to and extending between the front side of the backrest 6 and an upperside of the base 4 of the shell 2. There is a second rectangular reinforcing sheet 50 of the type described above, this being adhered to and extending between the rear side of the backrest 6 and the underside of the base 4 of the shell 2. 25 In this way the reinforcing sheets or laminate 40 and 50 sandwich a portion of the form giving seat shell 2 between them and provide reinforcement to both the backrest 6 of the seat shell 2 and the base 4, and prevent breakage of the seat shell 2 where the base 4 transitions into the backrest 6. 30 Referring now to Figures 5 and 6, where there is illustrated a child safety seat assembly 60 according to a third exemplary embodiment, the assembly comprising a form giving seat shell 2 of polymeric foam of the type discussed above. There are two rectangular reinforcing sheets 70 of the type described above, one each adhered to and 35 extending from the forward side of backrest 6, forward along the inside of one sidewings 8, around the forward edge of sidewing 8, rearward along the outerside of sidewing 8 and onto the rear side of the 0 backrest 6. In otherwords each sidewing 8 is sandwiched between portions of a reinforcing sheet or lamina 70. In this way the reinforcing sheets 70 provide reinforcement to both the backrest 6 of the seat shell 2 5 and the sidewings 8, and prevent breakage where the backrest 6 transitions into the sidewings 8. Referring now to Figures 7 and 8, where there is illustrated a child safety seat assembly 80 according to a fourth exemplary embodiment, the assembly comprising a form giving seat shell 2 of polymeric foam of the type discussed above. 0 The seat shell 2 of assembly 80 is reinforced by reinforcing sheets 20, 40, 50 and 70 (x2), each being as discussed above. In this way the reinforcing sheets 20, 40, 50 and 70 provide reinforcement to the base 4, backrest 6 and 5 the sidewings 8 of the seat shell 2, and prevent breakage in the transition regions between these portions. Referring now to Figures 9 and 10, where there is illustrated a child safety seat assembly 90 according to a fifth exemplary embodiment, the assembly comprising a form giving seat shell 2 of polymeric !0 foam of the type discussed above. The seat shell 2 of assembly 90 is reinforced by reinforcing sheets 40, 50 and 70, each being as discussed above. 25 The seat shell 2 is further reinforced by a reinforcing sheet 100 extending up a front side of the backrest 6, over the top edge of the backrest 6 and partway down the rear side of the backrest 6. Reinforcing sheet 100 is similar to reinforcing sheet 20, discussed above, but differs from this in as much as reinforcing sheet 100 extends further down both the front and rear sides of the backrest 6 than did rectangular reinforcing sheet 20. In this way, reinforcing sheet 100 surrounds all of the seat belt 30 apertures 12 located in the backrest 6, thereby reinforcing the seat shell 2 around all of these. As a result of the additional length, reinforcing sheet 100 now overlaps with the sidewing reinforcing sheets 70, providing additional reinforcement at these overlaps. Further extending reinforcing sheet 100 could further create overlap with reinforcing sheets 40, 50. 35 Referring now to Figures 11 and 12, where there is illustrated a child safety seat assembly 110 according to a sixth exemplary embodiment, the assembly 110 comprising a form giving seat shell 2a 0 of polymeric foam, which is almost identical to the seat shell 2 discussed above, differing only in that seat shell 2a is deficient the seatbelt apertures 12 of seat shell 2. The seat shell 2 of assembly 90 is reinforced by reinforcing sheets 40, 50 and 70 and 100 each being 5 as discussed above. Referring now to Figures 13 and 14, where there is illustrated a child safety seat assembly 120 according to a seventh exemplary embodiment, the assembly 120 comprising a form giving seat shell 2 of polymeric foam of the type discussed above. 0 The seat shell 2 of assembly 120 is reinforced by reinforcing sheets 40 and 50, each being as discussed above. The seat shell 2 of assembly 120 is further reinforced by three spaced apart reinforcing strips 130. Each reinforcing strip extends up a front side of the backrest 6, over the top edge of the backrest 6 and part way down the rear side of the back rest 6. One of these reinforcing strips 130 extends between 5 the two columns of seatbelt apertures 12, and there is a further strip 130 on either side of these columns of seatbelt apertures 12. Referring now to Figures 15 and 16, where there is illustrated a child safety seat assembly 140 according to an eighth exemplary embodiment, the assembly 140 comprising a form giving seat shell 2 '.0 of polymeric foam of the type discussed above. The seat shell 2 of assembly 140 is reinforced by reinforcing sheets 40 and 50, each being as discussed above. The seat shell 2 of assembly 120 is further reinforced by reinforcing sheets 150 and 160, which would collectively cover an area similar to reinforcing sheet 20 but for being separated along the top 25 edge of the backrest 6 of the seat shell 2. The seat shell 2 of assembly 120 is further reinforced by reinforcing sheets 170 and 180, which would collectively cover an area similar to reinforcing sheet 70 but for being separated along the forward edge of the sidewings 8 of the seat shell 2. 30 Referring now to Figures 17 and 18, where there is illustrated a child safety seat assembly 190 according to an eighth exemplary embodiment, the assembly 190 comprising a form giving seat shell 2 of polymeric foam of the type discussed above. 35 The seat shell 2 of assembly 190 is reinforced by a reinforcing strip 130 of the type described above, which extends between the two columns of seatbelt apertures 12. 10' The seat shell 2 of assembly 190 is further reinforced by four reinforcing strips 200 which are adhered to and extending from the forward side of backrest 6, forward along the inside of one sidewing 8, around the forward edge of sidewing 8, rearward along the outerside of sidewing 8 and onto the rear side of the backrest 6. 5 The seat shell 2 of assembly 190 is further reinforced by two reinforcing strips 210 which are adhered to and extending between the front side of the backrest 6 and an upperside of the base 4 of the shell 2, and the rear side of the backrest 6 and the underside of the base 4 of the shell 2. 0 Referring now to Figures 19 and 20, where there is illustrated a child safety seat assembly 220 according to a ninth exemplary embodiment, the assembly 220 comprising a form giving seat shell 2 of polymeric foam of the type discussed above. The seat shell 2 of assembly 220 is reinforced by reinforcing sheets 130, 200 and 210 each being as 5 discussed above. Seat assembly 220 differs from seat assembly 190 in as much as reinforcing strips 200 are convergent at their ends, and diverge as they extend around the wings 8. Referring now to Figures 21 and 22, where there is illustrated a child safety seat assembly 230 according to a tenth exemplary embodiment, the assembly 230 comprising a form giving seat shell 2 0 of polymeric foam of the type discussed above. The seat shell 2 of assembly 230 is reinforced by reinforcing sheets 40 and 50, each being as discussed above. 25 The seat shell 2 of assembly 230 is further reinforced by a specially shaped reinforcement element 250. This reinforcement element 250 is a sheet of reinforcing material of the above described type, but this has been specially shaped by cutting or stamping so as to have the shape of the blank 260 illustrated in Figure 23. 30 Blank 260 has a top edge portion 270, which will in use, extend over the top edge of the backrest 6 and down the rear side of this. A transition portion 275 bridges top edge portion 270 and a pair of side wing tabs 280 which extending outwardly to each side of the top edge portion 270. A cut out space 290 separates the two side wing tabs 280. 35 In use, with the top edge portion 270 extending over the top edge of the backrest 6 and down the rear side of this, the cut out space 290 provides clearance for the seatbelt apertures 12, and the sidewing tabs 280 extend forward and around the sidewings 8. 11 In this way, the one quickly and easily applied reinforcement element 250 has provided reinforcement for each of the backrest 6 and sidewings 8 of the seat shell 2. 5 While one form of booster seat 2 has been illustrated in the above discussed exemplary embodiments, it should be understood that the invention is not so limited. It has application in seats without sidewings 8, or indeed backrest portions 6, such as some booster seats. It also has application in seats incorporating height adjustable headrests which may in turn incorporate their own sidewing portions. It also has application in infant capsules, and indeed any form of seating or restraint product 0 incorporating foam portions. Similarly, while the invention relates broadly to juvenile seating products, it should be further understood that the invention is not so limited. 5 It will be understood that the term "comprise" and any of its derivatives (e.g. comprises, comprising) as used in this specification is to be taken to be inclusive of features to which it refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied. Any and all publications mentioned in this specification are herein incorporated by reference. Any .0 discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed in Australia or elsewhere before the priority date of each claim of this application. 25 Although the disclosure has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognised that departures can be made within the scope of the invention, which is not to be limited to the details described herein but is to be accorded the full scope of the appended claims so as to embrace any and all equivalent devices and apparatus. 12

Claims (17)

1. A child restraint apparatus for restraining a child within a vehicle, the child restraint apparatus comprising a seat shell having at least a portion with a pair of substantially oppositely directed surfaces or sides, and one or more lamina contiguously secured to both of these substantially oppositely directed surfaces or sides of the portion so as to thereby reinforce at least said portion of the seat shell.

2. The child restraint apparatus as in claim 1, wherein the lamina is a sheet or strip of flexible material.

3. The child restraint apparatus as in either of the preceding claims, wherein the lamina of reinforcing material is secured to the seat shell with an adhesive.

4. The child restraint apparatus as in any one of the preceding claims, wherein the lamina is shaped and/or adapted to provide optimised reinforcement for a specific surface or portion of the seat shell.

5. The child restraint apparatus as in any one of the preceding claims, wherein the pair of substantially oppositely directed surfaces or sides are reinforced by a single lamina.

6. The child restraint apparatus as in any one of claims I to 4, wherein the pair of substantially oppositely directed surfaces or sides are reinforced by way of one lamina secured to one surface or side, and a second lamina secured to the oppositely directed surface or side.

7. The child restraint apparatus as in any one of the preceding claims, wherein the pair of substantially oppositely directed surfaces or sides are an inner surface or side and an outer surface or side of the portion of the seat shell.

8. The child restraint apparatus as in any one of the preceding claims, wherein the or each lamina extends across, around or between at least two adjoining surfaces or portions of the seat shell.

9. The child restraint apparatus as in claim 8, wherein the two adjoining surfaces or portions of the seat shell reinforced are at least part of one or more of: a base and a backrest; and/or a backrest and a sidewing; and/or a base and a bolster; and/or 13 a headrest and a sidewing of a headrest.

10. The child restraint apparatus as in any one of the preceding claims, wherein all or part of the seat shell is made of a foam material.

11. The child restraint apparatus as in any one of the preceding claims, wherein the or each lamina is a thin sheet of strong but flexible polymer or plastic film.

12. The child restraint apparatus as in any one of the preceding claims, wherein at least portions of one side of the or each lamina of reinforcing material are covered with adhesive.

13. The child restraint apparatus as in any one of the preceding claims, wherein an entirety of one side of the or each lamina of reinforcing material is covered with adhesive.

14. The child restraint apparatus of claim 9, wherein the adhesive covered side of the or each lamina is further covered by a peel-off backing layer.

15. The child restraint apparatus of claim 14, wherein in use, this peel-off backing layer is removed prior to the application of the or each lamina of reinforcing material to the seat shell.

16. The child restraint apparatus as in any one of claims 1 through 11, wherein a lamina forming liquid is painted or sprayed onto all or part of the seat shell in liquid form, and this then provides its reinforcing properties when it dries or cures.

17. The child restraint apparatus as in any one of claims 1 through 11, wherein at least part of the seat shell is dipped into a lamina forming liquid, which will provide its reinforcing properties when it dries or cures. 14