GB2624459A

GB2624459A - Head restraint assembly

Info

Publication number: GB2624459A
Application number: GB2217361.1A
Authority: GB
Inventors: Ciobanu Ion-Daniel; Horsburgh Mike
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2022-11-21
Filing date: 2022-11-21
Publication date: 2024-05-22
Also published as: GB202217361D0

Abstract

A vehicle seat head restraint assembly 200 has a support 100 which is at least one plate 110, the at least one plate 110 having engagement means (e.g. apertures 120,122) for engaging with a head restraint mounting 162,164 of a seat to allow movement of the support 100, and the support 100 able to support components (e.g. aft trim 170, compressible pad 172, fore trim 174). Plate 110 can be steel with a return flange (114, fig 1) around its periphery and indented recesses across its surface (fig 1) to enhance rigidity. The plate can have two spaced parts with a cavity between.

Description

HEAD RESTRAINT ASSEMBLY

TECHNICAL FIELD

The present disclosure relates to a head restraint assembly. Aspects of the invention relate to a head restraint assembly for a vehicle seat, to a seat comprising the head restraint assembly and to a vehicle comprising a seat that comprises the head restraint assembly.

BACKGROUND

It is known to provide head restraints on vehicle seats, primarily for safety reasons although it will be appreciated that such head restraints may also have other advantages such as improving comfort for a seat user. Known head restraints comprise an internal frame which provides structural support and rigidity to the head restraint. The internal frame typically comprises a number of individual components, usually made of metal, which are secured together for example by welding, to produce a rigid, strong support structure around which other head restraint components, such as padding and other trim components can be fitted to produce the desired form of head restraint. The known head restraints can be time consuming to produce, as their construction relies on the production and subsequent assembly of a significant number of component parts of the frame. After the frame has been securely constructed, further assembly time is required to apply padding for the head restraint in the relevant area of the frame, and to secure usually multiple trim components, such as the fore and aft surfaces of the head restraint, to the frame. In many cases, external trim components such as the fore and aft surfaces, are provided in clam-shell form, for ease of fitting around the internally positioned support frame, but these clam-shell components typically require fixing together during assembly of the head restraint, such as by using screws or other suitable fasteners, thus increasing assembly time and necessitating the use of numerous fasteners.

It is an aim of certain embodiments of the present invention to address one or more of the

disadvantages associated with the prior art.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a head restraint assembly for a vehicle seat, a seat for a vehicle comprising a head restraint assembly, and a vehicle comprising a seat as claimed in the appended claims.

According to an aspect of the present invention there is provided a head restraint assembly, the head restraint assembly comprising a support, the support being defined by a at least one plate, the at least one plate having engagement means for engaging with a head restraint mounting assembly of a vehicle seat to allow movement of the support relative to a vehicle seat, and the support being configured to support one or more head restraint components.

Optionally, the at least one plate is substantially planar having a return flange around its periphery and a plurality of indented recesses distributed across its surface whereby the rigidity of the plate in its plane is enhanced.

By providing the support in the form of at least one plate, as compared to in the form of a frame comprising multiple component parts joined together, the support of the head restraint assembly according to certain embodiments of the present invention has numerous advantages over known, frame-based head restraint supports. Such advantages may include a reduction in weight of the head restraint, and reduced costs associated with manufacturing and assembly of the head restraint, due to the requirement to use fewer components to manufacture the plate-based support of the present invention as compared to the known frame-based support.

Assembly of a head restraint according to certain embodiments of the present invention is also simpler as compared to assembly of known head restraints comprising frame-based supports, because certain embodiments of the present invention comprise fewer components as compared to the known frames which comprise many individual parts joined together. Assembly of head restraints according to certain embodiments of the present invention may also be simplified by the ability to quickly and easily clip one or more head restraint components, such as trim components onto the support, for example via mounting means in or on the support, and or optionally via one or more return flanges on the support. Such embodiments allow for an easier and more rapid assembly of head restraint as compared to assembly of known head restraints which may require multiple component parts to be joined together and/or to the frame using fasteners, which can be time consuming.

The term "plate" is not intended to limit the support to any specific configuration, but instead is intended to define a generally planar piece or pieces of material used to define or form the support according to embodiments of the present invention. The generally planar piece(s) may be of any shape or size considered appropriate, and may comprise one or more projections/ recesses; apertures; fixing points or the like. In certain embodiments, the plate may be a solid, thin piece of material, optionally comprising one or more of the aforementioned features such as projections/ recesses/ apertures/ fixing points etc. The term "plate" may also, in certain embodiments, relate to more than one piece of generally planar material secured to one or more other pieces of generally planar material to form a solid, generally planar structure comprising multiple layers. Optionally, one or more of the layers may comprise cavities therebetween.

The term "head restraint components" is intended to define any component or material that may be attached to the support during assembly of the final form of head restraint. Head restraint components may include but not be limited to one or more of a compressible pad, a rigid component and/ or a cover material, such as an external cover material.

Certain embodiments of head restraint assembly according to the present invention may be of particular benefit for use in vehicles or other environments in which the seat package requirements are very restricted, such as for example, row 3 seats of a vehicle. In such environments, a head restraint assembly according to embodiments of the present invention and which can rotate about a pivot axis from an in-use position to a stowed position, where once in the stowed position, the head restraint is contained within a void in the backrest portion of the seat such that it forms a flush surface with the backrest portion of the seat.

Optionally, the support of the head restraint assembly may comprise a single plate. A head restraint assembly comprising a single plate for the support component may be advantageous in reducing the weight and depth of the side profile of the head restraint assembly, whilst still complying with requisite safety requirements.

Optionally, the support may comprise a return flange around the periphery of each of the one or more plates. Forming a return flange on the peripheral edge of the one or more plates is advantageous in that it increases strength of each of the plates, and can be used to secure one plate to another plate.

Optionally, the return flange may have a variable depth (i.e. distance between its peripheral edge and the edge of the return flange that is continuously formed with the fore/ aft facing surfaces of the plate(s)). For example, the return flange may have a lesser depth a top end of the one or more plates as compared to the bottom of the one or more plates, the top end being arranged, in use, generally adjacent a seat user's head, and narrower at a bottom end of the plate(s), the bottom end being arranged, in use, adjacent a backrest portion of a seat. Providing a greater depth of return flange at the bottom end of the support is advantageous because the greater depth in this region of the support creates space within the support to accommodate one or more head restraint components, such as but not limited to a pivot assembly, for enabling pivoting of the head restraint assembly about a pivot axis.

Optionally, the return flange may be configured to engage with or cooperate with one or more head restraint components, optionally, one or more trim components, to retain the one or more head restraints on the support. For example, the return flange may comprise engagement or securing means for enabling one or more trim components to be attached to the return flange.

Optionally, one or more edges of the one or more trim components (and/or other head restraint components) may be retained and optionally concealed within the return flange. Providing mounting means on the plate for securing or engaging one or more trim components to either the return flange of the support and/or to one or more other parts of the support may be advantageous in reducing assembly time, and reducing complexity of assembly of the head restraint assembly.

Optionally, mean for engaging or securing one or more trim components may be provided on one or more other areas of the support. Providing means for engaging or securing one or more trim components to one or more other areas of the support, i.e. not on the return flange, may be advantageous as it enables flexibility to attach trim components to different regions of the support according to specific requirements.

Optionally, said mounting means are apertures in a base of said recesses adapted to receive mounting clips extending from an internally facing surface of the one or more head restraint components. The engagement of mounting clips or securing means may comprise one or more of friction-fit fastening arrangements and/or clips. Friction-fit fastening arrangements and/or clips may be advantageous in providing a quick and simple means of attaching one or more trim components to the support.

Optionally, a first part of the plate may be arranged to overlie a second part of the plate to define a double wall configuration in at least part of the support. Overlying a second part of the plate with a first part of the plate (or vice versa) is advantageous as it provides an overlapping section in the support which may be secured using welding, fasteners or other bonding/ securing means, to prevent relative movement of the first and second parts of the plate.

Such an embodiment may be formed by folding over a single sheet (plate) to form the double wall configuration. By folding a single sheet in this way to form the double wall configuration, the amount of welding/ fasteners or other securement features required to hold the first and second parts of the single sheet (plate) in position in the double wall configuration is reduced, because the folded portion does not require any welding/ fasteners. In contrast, forming a double wall configuration using two distinct sheets or plates requires the entirety of the peripheral edges of plates to be secured together, such as by welding or fasteners, to eliminate any movement of the plates relative to each other.

Optionally, the first part of the plate may be joined to the second part of the plate to define the double wall configuration. Joining the first part of the plate and the second part of the plate, optionally wherein that joining occurs in the region where the first part of the plate overlies the second part of the plate, is advantageous in that it eliminates movement of the first part of the plate relative to the second part of the plate. This is advantageous because the aforementioned movement can cause the support to squeak and/or rattle under torsion which is undesirable.

For example, a peripheral edge of the first part of the plate may be joined to a peripheral part of the second part of the plate to define the double wall configuration. Joining peripheral edges of the plate in this way is advantageous because it eliminates movement of the first part of the plate relative to the second part of the plate. This is advantageous because the aforementioned movement can cause the support to squeak and/or rattle under torsion which is undesirable.

Optionally, the double wall configuration may comprise a cavity defined by a spacing between the first part and the second part of the plate. Providing a cavity between the two plates is advantageous in that it provides a weight and cost saving as compared to producing a comparatively sized solid support with no cavity.

Optionally, the first part may be joined to the second part via one or more welds. Welding is advantageous in the case of a support comprising metals, as the welded join provides a secure means of joining the first part and the second part of plate/ support.

The support may comprise more than one plate, wherein each of the more than one plate is formed from a different material or a different type of steel. Optionally, the one or more plates may comprise alloy steel. The provision of more than one plate wherein each of the more than one plate is formed from a different material or different type of steel, or alloy steel, is advantageous in that the structure of the support comprising more than one plate can be customised to suit requirements. For example, one of the plates may comprise mild steel for its ability to be more malleable for the purpose of achieving a particular shape during stamping of the plate, and another plate may comprise a medium carbon steel or high carbon steel for their increased strength properties as compared to mild steel. The resulting support would thereby benefit from both strength and an ability to more easily customise the shape and configuration of at least one surface of the support. Another potential advantage of using more than one plate to form the support is that material thicknesses between plates could be optimised to ensure a maximum weight saving during manufacturing of the support. Optionally, the support may comprise two plates. Optionally, the support may comprise more than two plates. The provision of two plates to form the support is advantageous in that it may further increase the strength of the support as compared to a support comprising a single plate, assuming that other variables such as the material used for each support are consistent between embodiments.

Optionally, the two plates may be secured together. Securing the two plates together is advantageous in that it eliminates movement of each of the two plates relative to each other. This is advantageous because the aforementioned movement can cause the support to squeak and/or rattle under torsion which is undesirable.

Optionally, the two plates may be secured together via one or more welds, and/or one or more fasteners, and/ or by another appropriate means of bonding the two plates together that is suitable for the particular material used for the plate. Welding is advantageous in the case of a support comprising metals, as the welded join provides a secure means of joining the first part and the second part of plate/ support.

Optionally, the two plates may be secured together at a peripheral edge to define a cavity between the two plates. For example, the two plates may be secured together in a clam-shell arrangement. Securing the two plates together at a peripheral edge is advantageous in that it eliminates any squeaks/ rattle associated with the two plates moving against each other under torsion when the head restraint is in use. The use of two plates for the support is advantageous in that it may provide increased strength to the support as compared to using a single plate, providing that other variables such as the material used for the plates is the same.

Optionally, the cavity in any embodiment may be tapered in cross-section. Tapering the cross-section of the cavity is advantageous in that it can reduce the amount of corresponding "cut out" (or recess) required in a backrest portion of a seat to which the head restraint will be fitted, and into which the head restraint will be stowed. Reducing the amount of cut out or recess in the backrest portion of the seat is advantageous as the smaller the cut out or recess, the more supported a user's back is while using the seat. A larger cut out or recess leaves the user's back largely unsupported which can be uncomfortable.

Optionally, the one or more plates may comprise one or more recesses. The one or more recesses are advantageous as they increase stiffness of the plate into which the recess or recesses are formed Optionally, the one or more plates may comprise one or more ridges or ribs. The one or more ridges or ribs are advantageous as they add strength to the plate by providing regions of additional material (i.e., the ridges/ ribs) which reinforce the plate structure to make it stronger.

Optionally, the recesses may be stamped or pressed into one or more of the plates. For example, the recesses (or raised portions/ projections) may be formed by using dies and stamping presses to press regions of sheet metal against a die that contains the desired shape, so as to emboss the corresponding shape into a sheet of metal in either a raised or recessed configuration. Stamping or pressing the recesses into the plate improves the speed and simplicity of manufacturing of the support, which can in turn help to reduce associated manufacturing costs.

Optionally, the one or more recesses may comprise one or more of the following: a circular recess, a curve-shaped recess and/or a linear recess. Varying the shape and/or size of each of the recesses may be advantageous in that each particular shape may provide a particular increase in strength, e.g. yield strength, and may assist in customising the strength properties of the plate to provide additional strength in particular regions of the plate via the provision of appropriately shaped and positioned recesses.

Optionally, the trim components may comprise one or more of a compressible pad, a cover material, such as an external cover material. The cover material may be rigid or flexible, or a comprise both rigid and flexible parts. Optionally, the rigid material may comprise plastics. Optionally, the external cover material may comprise a flexible material, such as a synthetic or natural fabric, or leather. Using a rigid material, such as a plastics material, may provide functional benefits to the head restraint assembly, such as improving its durability or improving the ease by which the trim component may be cleaned. Using a rigid material, such as a plastics material may also be aesthetically preferable in some environments. The provision of a flexible material is advantageous in that it improves comfort for the user when the user's head comes into contact with a rest surface of the head restraint assembly. The use of a flexible material is also advantageous in that it can easily conform to different shapes of head restraint assemblies. The provision of an external cover material provides the advantage of covering the underlying head restraint components, and provides the option for the external surface of the head restraint to be customised to suit a particular environment. For example, the external cover material may be selected to match or complement other trim components or structures in an environment such as in a vehicle cabin.

Optionally, the compressible pad may be mounted on a first side of one of the one or more plates. Optionally, the head restraint assembly may comprise a trim component mounted on a second side of one of the one or more plates. Providing an arrangement in which one or more trim components can be mounted on a first side and/or a second side of the one or more plates enables greater flexibility as to where trim component(s) may be placed so that the head restraint assembly can be customised to suit different requirements.

Optionally, the external cover material may be mounted over the compressible pad and/or the support. By mounting the external cover material over the compressible pad and/or the support, the compressible pad and/or the support of the head restraint assembly can be concealed so that only the external cover material is presented to the user, thus enhancing the aesthetic appeal of the head restraint assembly.

Optionally, the engagement means may comprise one or more apertures. The one or more apertures may be for engaging with a pivot element on a head restraint mounting assembly of a vehicle seat. The pivot element may, for example, comprise a rod which may be slid through each of the one or more apertures to enable the support to be joined to a pivot assembly of a head restraint mounting assembly of a vehicle seat. Such an arrangement may be advantageous in providing a head restraint assembly which can selectively pivot relative to a backrest portion of a seat.

Optionally, the head restraint may comprise a compressible pad. The compressible pad may be mounted on a first side of one of the one or more plates. The provision of apertures offers a simple and thus cost effect means of connecting the support with a head restraint mounting assembly on a vehicle seat, and/or for connecting the support to one or more other components, for example associated with a vehicle or seating arrangement.

Optionally, the head restraint assembly may comprise a trim component mounted on a second side of the plate. This may be advantageous in providing a different extemal feature, such as a different external trim cover on one side of the assembled head restraint assembly as compared to a trim cover mounted on the other side of the assembled head restraint assembly.

Optionally, the at least one plate may comprise mounting means for mounting one or more head restraint components onto the support. By way of non-limiting example, mounting means may comprise one or more fasteners, and/or snap fit connectors. The provision of mounting means is advantageous for improving ease and speed of assembly of the head restraint assembly because the mounting means allow for components, such as trim components, to be quickly and easily attached to the at least one plate.

Optionally, the at least one plate may comprise a stamped sheet. Optionally, the stamped sheet may comprise metal. Provision of a stamped sheet for the at least one plate improves the ease and speed of manufacturing of the plate. For example, multiple features of the at least one plate, such as recesses and/or apertures may be formed simultaneously during a plate stamping process, thus improving ease and speed of manufacturing.

Optionally, the at least one plate may be generally rectangular or square, or tapered in plan view, such as when viewed from the fore or aft surfaces of the at least one plate. The aforementioned shapes may be advantageous in providing a sufficient surface area to properly support a user's head in at least one region of the plate(s).

Optionally, in the case of a tapered embodiment of the at least one plate, the at least one plate may be wider at a top end of the plate, the top end being arranged, in use, generally adjacent a seat user's head, and narrower at a bottom end of the plate, the bottom end being arranged, in use, adjacent a backrest portion of a seat. The aforementioned shapes may be advantageous in providing a sufficient surface area to properly support a user's head in at least one region of the plate(s), whilst providing a narrower portion in another region of the plate which may be advantageous if that narrower portion is configured to sit in a corresponding recess or cut out in a backrest portion of the seat, whereby reducing the size of said recess/ cut out may be beneficial in terms of seat user comfort and/or aesthetic reasons.

Optionally, the at least one plate may not be tapered but may be formed to provide a larger portion of the plate at one end of the plate, for example the top end of the plate, and a smaller portion of the plate at the other end of the plate, for example the bottom end of the plate.

Providing the at least one plate in either a tapered form or in a form comprising a larger portion and a smaller portion, is advantageous for a number of reasons. For example, it can reduce the amount of materials required to form the plate and, optionally head restraint assembly comprising the plate. It can reduce the size of cut out required in a seat backrest portion to accommodate the bottom or lower end of the plate (i.e. part of the plate positioned closest to the backrest portion when the head restraint assembly is installed onto a seat), whilst still providing sufficient support to a user's head via the larger portion of the plate.

Optionally, the at least one plate may comprise metal. Using metal to form the at least one plate is advantageous because, in one or more embodiments, the metal may be easily cut to the required size, and optionally, features of the plate such as recesses or apertures may be stamped into the metal.

Optionally, the at least one plate may comprise sheet metal. Using sheet metal to form the plate is advantageous as it lends itself to a metal stamping process which may be used to add optional features to the at least one plate, such as recesses or apertures.

Optionally, the at least one plate may comprise steel. Using steel is advantageous as it provides the at least one plate with strength and rigidity arising from the material properties of the steel Optionally, the at least one plate may comprise mild steel. The term "mild steel" is to be interpreted in accordance with appropriate industry materials classification. For example, mild steel may be considered to cover steels containing up to 0.3% carbon. Use of mild steel to form the one or more plates is advantageous in that it is less expensive than other grade of steel, and possesses good formability which is advantageous when manufacturing the support.

Optionally, the at least one plate may comprise medium carbon steel, i.e. steel containing 0.31% to 0.6% carbon and 0.31% to 1.60% magnesium. Use of medium carbon steel to form the one or more plates is advantageous in that it is stronger than mild steel.

Optionally, the at least one plate may comprise high carbon steel, i.e. steel containing more than 0.6% carbon and 0.31% to 0.9% magnesium. Use of high carbon steel is advantageous in that it is stronger and harder than mild or medium steel.

According to another aspect of the present invention there is provided a seat for a vehicle, the seat comprising a head restraint assembly according to embodiments of the invention.

According to another aspect of the present invention, there is provided a vehicle, the vehicle comprising a seat according to embodiments of the invention.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a rear perspective view of a support for a head restraint assembly in accordance with an embodiment of the invention, the support being defined by a plate; Figure 2 shows an exploded view of a head restraint assembly in accordance with an embodiment of the invention, the head restraint assembly comprising the support shown in Figure 1; Figure 3 shows a cross-sectional view though the side of the head restraint assembly shown in Figure 2, in assembled form; Figure 4 shows a front view of the assembled head restraint assembly shown in Figure 3; Figure 5 shows a rear perspective view of the head restraint assembly shown in Figure 4; Figure 6 shows a side view of the head restraint assembly shown in Figures 2 and 3, in particular, a view of the external surface and profile of a side of the head restraint assembly; Figure 7 shows a side view of a head restraint assembly in accordance with another embodiment of the invention, the head restraint assembly of this embodiment comprising a tapered side profile; Figure 8 shows a front perspective view of a support for a head restraint assembly in accordance with another embodiment of the invention which comprises a first plate and a second plate which may be separate plates or formed from a single plate folded over to provide two, integrally formed plates; Figure 9 shows a rear perspective view of a support for the head restraint assembly shown in Figure 8 Figure 10 shows an exploded view of a head restraint assembly in accordance with another embodiment of the invention shown in Figures Band 9, comprising the support shown in those Figures; Figure 11 shows a cross-sectional view through the side of the head restraint assembly shown in Figure 10, in assembled form; Figure 12 shows a rear view of the assembled head restraint assembly shown in Figure 11; and Figure 13 shows a vehicle in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

A head restraint assembly 200 in accordance with an embodiment of the present invention is described herein and with reference to the accompanying Figures 1 to 7.

With reference to Figure 1, there is illustrated a support 100 for a head restraint assembly 200. The support 100 comprises a plate 110. The term "plate" is intended to reflect a generally planar component which may comprise one or more sheets or "skins" of metal, or any other material suitable for purpose. The generally planar component ("plate") may comprise one or more folded portions, such as a return flange around its periphery. In the present embodiment, the plate 110 is formed from sheet metal, in particular, steel. It will be appreciated that other materials may suitably be used to form the plate 110. By way of non-limiting example, composite materials or a metal casting may be suitable for forming the plate. In one or more embodiments, the sheet metal forming the plate is around 1 to 2mm in thickness. In one or more embodiments, the sheet metal may be of a thickness of less than 1mm or more than 2mm. The plate 110 comprises a generally rectangular surface 112 having a return flange 114 around its periphery, and comprises a first end 116 and a second end 118. More specifically, the generally rectangular surface 112, herein after referred to as the rectangular surface 112, comprises a first part 112a and a second part 112b, the first part 112a being defined by a substantially square shaped region extending between the first end 116 and approximately midway between the first end 116 and the second end 118, and the second part 112b being defined by a substantially rectangular shaped region extending between the second end 118 and approximately midway between the first end 116 and the second end 118. The first part 112a and the second part 112b are integrally formed with one another as part of the same sheet metal plate 110. In the present embodiment, the first part 112a of the plate 110 is wider than the second part 112b of the plate so as to create a shoulder region 113 between the first part 112a and the second part 112b of the plate 110. The shoulder region 113 may be formed by pressing the second part 112b of the plate 110 inwardly during formation of the plate to make it narrower than the first part 112a of the plate 110, thus creating the shoulder region 113 between the first part 112a and the second part 112b.

The rectangular surface 112 has a fore surface 112c and an aft surface 112d. The fore and aft surfaces or sides 112c, 112d are defined in the context of installation of the support 100 in a head restraint assembly 200 in a vehicle 500, in which the fore surface 112c is defined as being the surface closest to and facing the front of the vehicle 500, and the aft surface 112d is the surface closest to and facing the rear of the vehicle 500 when the head restraint assembly 100 is in a deployed position, such as illustrated in Figures 4 and 5. The second part 112b of the plate comprises a slightly curved profile such that the aft surface 112d is slightly concave and the fore surface 112c is commensurately slightly convex when the plate is viewed from the first side surface 124 or the second side surface 126. The concavity in the aft surface 112d assists in accommodating a pivot mechanism (not illustrated in Figure 1) for moving the support between a stowed position and an in-use position, when the support 100 forms a part of a head restraint assembly.

The return flange 114 defines an enclosing wall 114 around the edge of the plate 110, which plate itself defines the principle shape, in the fore-aft direction of view, of the head restraint assembly of which it forms a part. At the first end 116, the return flange 114 comprises first and second circular apertures 120, 122. The first circular aperture 120 is located on a first side surface 124 of the return flange 114 and the second circular aperture 122 is located opposite to the first circular aperture 120, on a second side surface 126 of the return flange 114. The first circular aperture 120 and second circular aperture 122 each comprise an annual flange 120a, 122a, extending perpendicularly away from the return flange 114. The annular flanges 120a, 122a coaxially surround a rod 160 which is part of the head restraint assembly (described later and shown in Figure 2), so that the support 100 can be mounted onto a backrest of a seat. The return flange 114 is of a greater depth at the first end 116 of the plate 110 as compared to the second end 118, for the purpose of accommodating the first and second circular apertures 120, 122, such that the profile of return flange 114 tapers from the first end 116 to the second end 118. This greater depth of return flange 114 at the first end, in combination with the above-mentioned concavity of the aft surface 112d in the second part 112b of the plate 110, assists in accommodating and concealing an underlying pivot mechanism (or other seat back attachment mechanism) that would be attached to the support when the support 100 is part of a head restraint assembly. The greater depth of return flange at the first end 116 of the plate 110 (or, in other embodiments which may or may not comprise a return flange, the provision of a greater depth of plate at the first end of the plate as compared to the second end) also enables the plate 110 to withstand loading that will be transferred through that region of the plate, and through the underlying pivot mechanism when the head restraint is in use, and in particular in a crash scenario when the head restraint assembly will be subjected to increased loading.

A lesser depth of return flange at the second end 118 of the plate 110 (or, in other embodiments which may or may not comprise a return flange, the provision of a lesser depth of plate at the second end of the plate as compared to the first end) allows for an increased depth of compressible pad to be attached to the fore surface of the plate 110 to provide increased comfort for the user of the head restraint assembly without significantly increasing the depth of the head restraint assembly as a whole.

The plate 110 comprises a plurality of depressions or recesses in the generally rectangular surface 112 and in the return flange 114, as will be described more fully. The recesses are stamped into the rectangular surface 112 and return flange 114 of the plate 110 using a known metal stamping process. In the present embodiment, stamping of the plate 110 occurs in the fore-aft direction. In other words, during the metal stamping process, pressure is applied to regions of the fore surface 112c of the plate 110 to push those regions in the aft direction to create recesses in the fore surface 112c. However, in one or more embodiments, the first and second circular apertures 120, 122 and their associated annular flanges 120a, 122a are not stamped in the fore-aft direction, as can be readily inferred with reference to Figure 1 for example, but are instead created by stamping a hole through the return flange 114 in a medial-lateral direction, i.e. from the inside surface of the return flange 114 towards the outside surface of the return flange 114. The size, shape, configuration and relative positioning of the recesses on the plate 110 can vary between different embodiments of the invention. An example arrangement of recesses is described below.

In the present embodiment, the plate 110 comprises two spaced apart circular recesses, 128, 130 hereinafter referred to as the first recess 128 and second recess 130 which are transversely positioned approximately around the midline of the first part 112a of the plate 110, and spaced either side of a longitudinal midline of the first part 112a of the plate 110. A curved recess 132 is transversely positioned below the first and second recesses 128, 130, i.e. in a direction away from the second end 118 of the plate 110. The first recess 128, second recess 130 and curved recess 132 are collectively surrounded by a recess in the form of a circular channel, hereinafter, the circular channel recess 134. The circular channel recess 134 comprises a curved profile, as represented on Figure 1 by the concentric lines of the recess 134. Collectively, the relative positioning of the first recess 128, second recess 130, curved recess 132 and circular channel recess 134 might be colloquially viewed as a "smiley face" formed in the first part 112a of the rectangular surface 112 of the plate 110. It is to be appreciated that this particular positioning is not an essential feature of the invention and that other shapes, sizes and configurations of recess may be used in one or more other embodiments of the invention.

The first part 112a of the plate comprises three circular recesses 136, 138, 140 spaced equidistance apart on the rectangular surface 112, adjacent the part of the return flange 114 running along the edge of the second end 118, as shown in Figure 1.

The first part 112a comprises two lateral recesses 142, 144 transversely positioned between the three circular recesses 136, 138, 140 and the shoulder 113, and substantially in line with lateral edges of the curved recess 132 and extending inwardly from the return flange 114, as shown in Figure 1. The medial end of each of the two lateral recesses 142, 144 is semi-circular in shape.

The shoulder region 113 comprises two lateral recesses 146, 148 extending inwardly from the return flange 114, as shown in Figure 1. The medial end of each of the two lateral recesses 146, 148 is semi-circular in shape. Positioned between each of the lateral recesses 146, 148 and the respective circular aperture 120, 122 is a generally semi-circular recess 147, 149 stamped into the peripheral edge of the return flange 114.

Each of the recesses optionally comprises at least a first reinforcing shoulder 141. The reinforcing shoulder 141 reinforces the structure of the respective recess, thus increasing the strength of the plate 110 as a whole when the plate 110 comprises multiple recesses and multiple reinforcing shoulders 141, 143. The term "reinforcing shoulder" is intended to define a stepped part of the recess. The stepped part of the recess is a boundary between consecutive sections of the recess. The consecutive sections may comprise different diameters such that the shape of the recess as a whole adopts a tapered profile, or frustoconical profile.

Each of the three circular recesses 136, 138, 140 along the second end 118 of the plate 110, and the lateral recesses 142, 144, 146, 148 extending inwardly from the return flange 114 comprises two reinforcing shoulders 141, 143, which provide structural strength to each recess 136, 138, 140, 142, 144, 146, 148. Each of these aforementioned recesses also comprises a rectangular aperture 145. The rectangular aperture 145 is located in the base of the recess. Each rectangular aperture 145 is configured to receive mounting clips 171 extending from an internally facing surface of a trim component so that the support 100 can be surrounded by one or more trim components, forming part of a head restraint assembly 200, as shown in Figure 2. The shape of each of the aforementioned circular recesses 136, 138, 140 is slightly frustoconical as the diameter of the open end of each recess 136, 138, 140 is slightly wider than the diameter of the closed base of the respective recess 136, 138, 140. The diameter of each recess 136, 138, 140 decreases slightly between each reinforcing shoulder 141, 143.

Consequently, in the present embodiment, each reinforcing shoulder 141, 143 is of a smaller diameter than the preceding reinforcing shoulder 141, 143, going in a direction towards the base of the recess 136, 138, 140 as can be seen on Figure 1.

The second part 112b of the plate 110 comprises a first elongate recess 150 and a second elongate recess 152, each extending between the shoulder region 113 and the circular apertures 120, 122. The first elongate recess 150 is positioned substantially midway between a longitudinal midline of the second part 112b of the plate and the first side surface 124 of the return flange and the second elongate recess 152 is positioned substantially midway between the longitudinal midline of the second part 112b of the plate and the second side surface 126 of the return flange. Positioned between the terminus of each of the first and second elongate recesses 150, 152, towards the first end 116 of the plate and substantially on the longitudinal midline of the second part 112b is a circular recess 154. The circular recess comprises a first reinforcing shoulder 141 and a second reinforcing shoulder 143. A wedge shaped recess 156 is also provided in the first end 116 of the plate 110, adjacent the second side 126 of the return flange.

The support 100 is integrated into a head restraint assembly 200 such as that shown in Figures 2 to 7. The plate 110 is attached to a head restraint mounting assembly 158 by sliding a rod 160 through each of the first and second circular apertures 120, 122 in the first end 116 of the plate 110. Each end of the rod 160 is slid into a respective mounting bracket 162, 164 which is affixable to a backrest of a seat by using fasteners (not shown) threaded through apertures 166a, 166b, 168a, 168b on each mounting bracket 162, 164 and secured into corresponding securement points (not shown) on the backrest of the seat. In one or more embodiments, the mounting assembly 158 may comprise a pivot mechanism for pivoting the support 100 relative to the backrest of the seat.

Trim components are attached to the plate 110 to conceal the plate 110 and add comfort and aesthetic properties to the plate 110, to form the head restraint assembly 200. Trim components include an aft trim component 170, which generally conforms to the size and shape of the plate 110, a compressible pad 172, for providing the head restraint assembly 200 with padding to improve user comfort, and a fore trim component 174, which generally conforms to the size and shape of the plate 110. The aft trim component 170 is attached to the aft surface 112d of the plate 110 by inserting each of the mounting clips 171 extending from an interior facing surface 170a of the aft trim component 170 into the corresponding rectangular aperture 145 in each of the three circular recesses 136, 138, 140 and the lateral recesses 142, 144, 146, 148 of the plate 110. The outer facing surface 170b of the aft trim surface 170 defines an aft surface of the head restraint assembly 200. The peripheral edge of the aft trim component 170 is concealed within the return flange 114 of the plate 110 once the aft trim component 170 has been attached to the plate 110 as described. The compressible pad 172 is placed on the fore surface 112c of the plate 110 for providing a cushioned surface for the seat user's head once the head restraint assembly 200 has been assembled. The compressible pad 172 is generally square shaped having rounded corners at one end for positioning adjacent corresponding rounded corners of the second end 118 of the plate, and tapering inwardly at the other end for positioning adjacent corresponding tapered edges in the shoulder region 113 of the first part 112a of the plate 110. The fore trim component 174 is placed over the compressible pad 172. The outer facing surface 174a of the fore trim component 174 defines a fore surface of the head restraint assembly 200. The fore surface provides support to a seat user's head when the head restraint assembly 200 is in use, fitted to a backrest of a seat. The fore trim component 174 comprises a return flange 176 around its periphery. The depth of the return flange 176 corresponds to the depth of the compressible pad 172. The edge of the return flange 176 is adapted to securely engage with the peripheral edge of the plate 110 and overlap with the edges of the aft trim component 170 attached to the aft surface 112d of the plate 110 to encase the plate 110 and the compressible pad 172 within the fore and aft trim components 174, 170 to provide the head restraint assembly 200 such as illustrated in Figs. 3 to 6.

The trim components of the head restraint assembly may be of a different shape and/or size as compared to those shown and described in relation to Figures 3 to 6. For example, the head restraint assembly may comprise a tapered profile when viewed from the side, such as illustrated in Figure 7. The different embodiment of head restraint assembly 200a shown in Figure 7 is otherwise constructed as described above and comprises a support 100 in accordance with an embodiment of the present invention.

A head restraint assembly 1200 in accordance with another embodiment of the present invention is described herein and with reference to the accompanying Figures 8 to 12.

Referring to Figures 8 to 12, a support 1100 for a head restraint 1200 in accordance with a further embodiment of the present invention is illustrated and will be described with reference to Figures 8 and 9. A head restraint assembly 1200 comprising the aforementioned support 1100 is illustrated and will be described with reference to Figures 10 to 12.

The further embodiments of support 1100 and head restraint assembly 1200 have features corresponding to features described above in relation to the first-described support 100 and head restraint assembly 200. These corresponding features will be identified using the same reference numerals as used above in relation to the first-described support 100 and head restraint assembly 200, prefixed with a leading "1". In general terms, the most notable differences between the further embodiment of support 1100 as compared to the afore-described embodiment of support 100 is that the further embodiment of support 1100 comprises a different arrangement of recesses stamped into the support 1100, and the further embodiment of support 1100 comprises a first plate and a second plate instead of a single plate. However, it is to be appreciated that one or more embodiments of support may comprise a first plate and a second plate which are integrally formed, such as by being formed from a single sheet of metal or other material folded over. In such embodiments, the integrally formed first and second plates may be secured together by abutting or overlapping an edge or a return flange on one plate with a return flange or peripheral edge of the other plate, and fixing those abutted or overlapping flanges/ edges using fasteners, and/or welds and/or rivets and/or any other suitable joining means.

Referring to Figures 8 to 10, the support 1100 comprises a first plate 1110 and a second plate 1111. The first plate 1110 and the second plate 1111 are generally the same shape as the plate 110 described above in relation to the aforementioned embodiment of support 100 and so the general shape will not be explicitly described in relation to this embodiment. As with the above-mentioned embodiment of support 100, the first plate 1110 and the second plate 1111 of the present embodiment of support 1100 each comprises a steel sheet which is stamped using a known metal stamping process to add recesses and/ or apertures, as will be described.

The first plate 1110 and the second plate 1111 each comprise a respective return flange 1114, 1115. The respective return flanges 1114 and 1115 inter-engage with one another to join the first plate 1110 and the second plate 1111 together with a cavity 1113 therebetween (shown in Fig. 11), to form the support 1100 according to this embodiment of the invention. The cavity 1113 in the present embodiment is tapered such that the fore-aft depth of the cavity is of a greater depth towards the first end 1116 of the support 1100 as compared to at the second end 1118.

In one or more embodiments, the return flanges 1114, 1115 may be welded together for additional strength although this is not necessarily essential. In one or more embodiments, the first plate 1110 and the second plate 1111 may be replaced by a single sheet which is folded over upon itself, optionally with a cavity between the folded parts, such that a part of the sheet defines a fore surface or "plate" and another part of the sheet defines an aft surface or "plate" of the support 1110. In one or more embodiments, the sheet metal first and second plates 1110, 1111 are formed of metal which is around 1 to 2mm in thickness. In one or more embodiments, the sheet metal may be of a thickness of less than 1mm or more than 2mm.

The first plate 1110 comprises a plurality of recesses which are in common with the corresponding recesses described above in relation to the abovementioned embodiment, in terms of their shape, size and relative positioning on the plate 1110, also as shown in Figures 8 and 9. Specifically, the first plate 1110 comprises a circular channel recess 1134 in a first part 1112a of the plate 1110, and first and second elongate recesses 1150, 1152, and a circular recess 1154 positioned midway between the terminus of each of the first and second elongate recesses 11510, 1152 in a second part 1112b of the plate 1110. A wedge shaped recess 1156, 1157 is provided between the terminus of each of the elongate recesses 1150, 1152 and the return flange 1114 of the first plate 1110, generally as per the above-mentioned alternative embodiment of support 100. Also generally as per the above-mentioned alternative embodiment of support 100, the first plate 1110 of the present embodiment comprises first and second circular apertures 1120, 1122 in the return flange 1114 at the first end 1116 of the first plate for attaching the support 1100 to a rod 1160 of a head restraint mounting assembly 1158. The head restraint mounting assembly 1158 illustrated in Figure 9 and described in relation to the present embodiment is the same as that described above in relation to the previous embodiment of support 100.

In contrast to the above-mentioned embodiment of support 100, in the present embodiment, the first plate 1110 comprises a second circular channel recess 1135 coaxially positioned inside of and spaced apart from the first circular channel recess 1134. In this embodiment, the second circular channel recess 1135 replaces the first recess 128, second recess 130 and curved recess 132 which collectively formed the "smiley face" recess arrangement described in relation to the above-mentioned embodiment of support 100. This example of the different arrangement of recesses demonstrates that embodiments of support according to the invention may take different forms.

As illustrated in Figure 9, the second plate 1111 comprises a plurality of intersecting recesses stamped into its surface. Specifically, the second plate 1111 comprises first and second elongate recesses 1180, 1182 spaced apart and extending substantially between the first end 1116 and the second end 1118 of the second plate 1111. For the avoidance of doubt, the "first end" and "second end" of the second plate 1111 correspond to the first end 116 and the second end 118, respectively, of the plate 110 of the above-mentioned embodiment of support 100. Perpendicularly intersecting the first and second elongate recesses 1180, 1182 are three further spaced apart elongate recesses, hereinafter third, fourth and fifth elongate recesses 1184, 1186, 1188, extending substanfially the width of second plate 1111, i.e. terminating just medial of the lateral edges of the second plate 1111 as shown in Figure 9.

As shown in Figures 10 to 12, the present embodiment of support 1100 is encased by trim components to form a head restraint assembly 1200 according to an embodiment of the invention. As with the aforementioned embodiment, the present embodiment of head restraint assembly 1200 comprises the trim component including a compressible pad 1172 which is positioned between the first plate 1100, and a fore trim component 1174, substantially as described above in relation to the previous embodiment of head restraint assembly 200.

The plate 110, 1100 replaces the traditionally used support frame in the head restraint assembly 200, 1200. Since known support frames typically comprise a number of interconnected components, replacing the frame with a support 100, 1100 according to embodiments of the present invention significantly simplifies the structure of the head restraint assembly 200, 1200, thus reducing costs and manufacturing complexities associated with producing the head restraint assembly, without compromising safety.

It is to be appreciated that the combination, shape, form and arrangement of each of the recesses of the embodiments of support 100, 1100 described herein may differ in other embodiments according to the present invention. The described and illustrated embodiments are not intended to limit the size, shape, configuration and/or combination of the recesses in the support and it will therefore be appreciated that a support in accordance with other embodiments of the present invention may comprise recesses having different sizes, shapes, configurations and relative arrangements.

The head restraint assemblies 200, 1200 described herein are installed in a vehicle 500, as shown in Figure 13. The vehicle in the present embodiment is an automobile, such as a wheeled vehicle, but it will be understood that the support for a head restraint assembly and the head restraint assemblies described herein may be used in other types of vehicle, such as aircraft, trains, etc. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

CLAIMS1. A head restraint assembly, the head restraint assembly comprising a support, the support being defined by at least one plate, the at least one plate having engagement means for engaging with a head restraint mounting assembly of a vehicle seat to allow movement of the support relative to a vehicle seat, and the support being configured to support one or more head restraint components.
2. A head restraint assembly according to claim 1, wherein the at least one plate is substantially planar having a return flange around its periphery and a plurality of indented recesses distributed across its surface whereby the rigidity of the plate in its plane is enhanced.
3. A head restraint assembly according to claim 1 or 2, comprising a single plate having a return flange around its periphery, optionally wherein the return flange comprises a variable depth.
4. A head restraint assembly according to claim 2 or 3, wherein the return flange is configured to engage with one or more of the one or more head restraint components to retain the one or more the head restraint components on the support.
5. A head restraint assembly according to claim 2, 3 or 4, wherein a first part of the plate is arranged to overlie a second part of the plate to define a double wall configuration in at least part of the support, optionally wherein the first part is joined to the second part via one or more 25 welds.
6. A head restraint assembly according to claim 5, wherein the first and second parts comprise two plates secured together in a spaced apart configuration to define a cavity between the two plates, optionally wherein the cavity is tapered in cross-section.
7. A head restraint assembly according to any preceding claim, wherein the at least one plate comprises mounting means for mounting the one or more head restraint components onto the support.
8. A head restraint assembly according to claim 7, when dependent on claim 2, wherein said mounting means are apertures in a base of said recesses adapted to receive mounting clips extending from an internally facing surface of the one or more head restraint components.
9. A head restraint assembly according to any preceding claim, wherein the one or more head restraint components comprises one or more trim components, optionally wherein the one or more trim components comprises one or more of a compressible pad, a flexible cover material, and a rigid cover material.
10. A head restraint assembly according to claim 9, wherein the one or more trim components are mounted on a first side of the plate, optionally wherein the one or more trim components mounted on the first side of the plate comprises a compressible pad.
11. A head restraint assembly according to claim 10, comprising a trim component mounted on a second side of the plate, optionally wherein the trim component comprises a rigid material.
12. A head restraint assembly according to any preceding claim, wherein the engagement means comprises one or more apertures for engaging with a pivot element on a mounting assembly of a vehicle seat.
13. A head restraint assembly according to any preceding claim, wherein the at least one plate comprises metal, optionally wherein the at least one plate comprises steel.
14. A seat for a vehicle, the seat comprising a head restraint assembly according to any preceding claim.
15. A vehicle comprising a seat according to claim 14.