WO2002079000A1

WO2002079000A1 - Recliner mechanism

Info

Publication number: WO2002079000A1
Application number: PCT/US2002/010016
Authority: WO
Inventors: Daniel J. Sakkinen
Original assignee: Johnson Controls Technology Company
Priority date: 2001-04-02
Filing date: 2002-04-01
Publication date: 2002-10-10

Abstract

A cast seat back frame is disclosed. The seat back frame incorporates part of the recliner mechanism, as a casting, directly in the seat back frame which is preferably cast of magnesium. The recliner mechanism includes a pivoting pawl and a cast sector whose periphery is partially covered with cast gear teeth to engage the gear teeth of the pawl for adjustment of the seat back frame. The seat back frame pivots about an axis that interfaces with the seat cushion and the seat back frame. The portion of the recliner mechanism that is integrally cast in the seat back frame may take on a variety of alternative embodiments. Those alternatives comprise an integrally cast semi-circular rack gear that interfaces with a pinion gear, an integrally cast socket joint that interfaces with a ball to form a ball and socket joint, and a hub having apertures through which a plurality of pawls pass to engage a ring sector having internal gear teeth to lock the seat back frame after adjustment of a handle shaft.

Description

RECLINER MECHANISM

FIELD OF THE INVENTION

[0001] The present invention generally relates to seat assemblies for motor vehicles. More particularly, the present invention relates to an integrated recliner mechanism for an automotive seat back frame.

BACKGROUND

[0002] Automotive seat recliner mechanisms are a common feature employed in automotive seats to provide a means of adjustment to accommodate a wide range of individual driver and passenger seat back positions. Known seat back recliner mechanisms are generally assembled from a large quantity of steel parts. Known recliner mechanisms also utilize springs to achieve the desired seat back position. The steel part assemblage would then be fastened to the automotive seat back frame by using rivets, bolts, welds or similar fastening devices.

[0003] The problems with known seat back recliner mechanisms are functional and economical. For example, known recliner mechanisms are relatively heavy due to their materials and quantity of parts. Such known recliner mechanisms must be assembled and then mechanically fastened and fitted to the seat back frame using bolts or rivets. This process is time consuming and requires installer skill to ensure that all parts are fitted and operating properly. This fastening of a collection of parts and associated springs is an opportunity for squeaks, rattles and general development of looseness of fit in the recliner mechanism itself which generally results in decreased performance and utility of the recliner mechanism. Additionally, such known recliner mechanism arrangements are typically manufactured using close tolerance processes which require many individualized manufacturing finishing steps and associated measurements. This results in a high manufacturing cost of the recliner mechanisms. Additionally, because these known recliner mechanisms are typically fastened to the side of a seat back frame, the dynamic load transfer path during the rear-ending of the vehicle typically does not follow a path directly through the seat pivot points and into the seat frame and automobile floor, but rather, is skewed to a side and results in seat buckling and mechanism failure, typically at the point of the recliner mechanism due to the large quantity of fastened parts.

[0004] While many other known seat back recliner mechanisms have proven to be commercially acceptable for their intended applications, all are subject to improvement. Accordingly, it would be advantageous to provide a recliner mechanism that reduces the weight of the recliner mechanism. It would also be advantageous to provide a recliner mechanism that reduces the current number of parts and associated manufacturing costs. It would also be advantageous to provide a recliner mechanism that improved the load transfer path during an accident. It would also be advantageous to provide a recliner mechanism that increases the strength of the recliner mechanism directly casting it with the seat back or cushion frame. It would also be advantageous to provide a recliner mechanism that reduces the complexity of the recliner mechanism and/or the potential for squeaks and rattles.

SUMMARY OF THE INVENTION

[0005] In accordance with the teachings of the present invention, a seat back recliner mechanism is provided that overcomes the problems and disadvantages of the conventional techniques in the art. It is a principal object to provide an adjustment mechanism to accommodate a wide range of seat positions for the driver or passenger of an automobile. It is also an object to reduce the number of parts within a seat back recliner mechanism, and the number of manufacturing processes to manufacture the related mechanism parts. Additionally, reducing the weight and improving the reliability of the recliner mechanism is an object of the invention. Lastly, improving the load transfer path of the seat back assembly and the seat occupant is an additional object. [0006] In another embodiment, a recliner mechanism for a seat mounted to a floor is comprised of an integrally cast hub adapted to be provided on the seat back frame, said integrally cast hub having a raised portion defining a space, one or more pawls slidably coupled to said adjustment plate and disposed in the space, a ring sector configured to coact with the pawls between an engaged position and a disengaged position, and an adjustment plate configured to move the pawls between the engaged position and the disengaged position. The integrally cast hub may be configured to provide a load path for force to travel through the seat back frame and said mechanism and into the floor upon a force being applied from a rearward direction in which said mechanism is installed. The hub may include one or more apertures and each pawl includes a pin extending through one of said aperture. An adjustment plate having one or more slots may be provided to correspond to said apertures in said hub.

[0007] In another embodiment, a recliner mechanism is comprised of an integrally cast recliner mechanism in the seat back frame. This integrally cast recliner mechanism is a circular sector ring having gear teeth that interface with a separate adjusting pawl and its gear teeth. The pawl is operated to change the position of the seat back frame.

[0008] In another embodiment, an integrally cast portion of the seat back frame comprises a semi-circular rack gear which interfaces with a pinion gear to adjust the seat back and achieve the desired seat back positions.

[0009] In another embodiment, an integrally cast portion of the seat back frame comprises a socket joint to interface with a separate piece comprising a ball. The ball and socket pieces result in a ball and socket joint and permit the seat back frame to pivot and adjust to the desired position of the seat occupant. Each recliner mechanism will be accompanied with an associated cap or cover to conceal the mechanism.

[0010] Additional objects, features, and advantages will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying preferred and exemplary embodiments as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

[001 1 ] Further features and advantages will become apparent from the following discussion and accompanying drawings, in which:

[0012] FIGURE 1 is a perspective view of an automobile seat cushion and a seat back showing the desired pivot point where the two components meet;

[0013] FIGURE 2 is a side schematic view of an automobile seat showing in phantom, exemplary positions that an automobile seat back may employ;

[0014] FIGURE 3 is a fragmentary side schematic view of an automobile seat back frame employing a pawl and sector arrangement whereby the pawl is used to adjust the seatback position;

[0015] FIGURE 4 is a fragmentary side schematic view of an automobile seat back frame employing a rack and pinion gear arrangement whereby the pinion gear rotates to adjust the seatback position;

[0016] FIGURE 5 is a fragmentary side schematic view of an automobile seat back frame employing a ball and socket joint arrangement whereby the ball is horizontally translated to adjust the seatback position;

[0017] FIGURE 6 is a fragmentary side schematic view of an end cap to cover a ball and socket joint mechanism or other mechanism;

[0018] FIGURE 7 is a fragmentary schematic view of an automobile seat back frame with a hub employing apertures to permit pawls to pass through the apertures;

[0019] FIGURE 8 is a side schematic view of three pawls that would typically pass through the apertures of FIGURE 7;

[0020] FIGURE 9 is a side schematic view of a pawl of FIGURE 8 with its associated adjustment rod; [0021] FIGURE 10 is a side schematic view of an adjustment plate which is used to move the pawls of FIGURE 8 against the ring sector of FIGURE 1 1 ;

[0022] FIGURE 1 1 is a side schematic view of a ring sector having gear teeth to mesh with the teeth on the pawls shown in FIGURE 8;

[0023] FIGURE 1 2 is an exploded, fragmentory schematic view showing FIGURES 7 through FIGURE 1 1 ;

[0024] FIGURES 1 3A and 1 3B are side schematic views of an adjustment plate for the recliner mechanism of FIGURE 1 2 according to alternative embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] The following description of the preferred embodiments is merely exemplary in nature, and is in no way intended to limit the invention, its application, or uses.

[0026] With reference to FIGURE 1 of the drawings, a reclining seat 1 0 is shown. Reclining seat 10 includes a seat back 1 2, a seat cushion 1 4, and a recliner mechanism 1 6. Recliner mechanism 1 6 is intended to reduce the manufacturing costs, the weight, the complexity and the number of parts within the recliner mechanism. Additionally, recliner mechanism 1 6 is intended to improve the load transfer path of the seat and occupant during a rear end collision of the seat occupant's automobile, and improve the overall reliability of the recliner mechanism.

[0027] FIGURE 2 illustrates, relative to the seat cushion 14, the multiple positions that are achievable with the automobile seat back 1 2 by adjusting recliner mechanism 1 6. Force arrow 1 5 shows the desired load path of the seat back 1 2 and the contents (not shown) of the automobile seat 1 0 in the event that the automobile in which the automobile seat 10 is installed, is struck from behind by a force 1 3. Referencing FIGURES 2 and 3, the desired load path of a force 1 5 is through the seat back frame 1 7, recliner mechanism 1 6, seat cushion frame 1 9, and into the automobile floor 1 1 . This desired load path decreases the likelihood that the recliner mechanism 1 6 will distort upon impact of rear force 1 3 and cause the total failure of the automobile seat 1 0 and recliner mechanism 1 6 and subsequent injury to an automobile seat occupant (not shown). According to alternative embodiments, recliner mechanism 1 6 may have any of a variety of attachment points using a variety of attachment mechanisms which may alter or change the load path through the attachment point. Additionally, recliner mechanism 1 6 may be cast to seat back frame 1 7 or seat cushion frame 1 9.

[0028] With reference to FIGURE 3, recliner mechanism 1 6 for an automobile seat back frame 1 7 according to an exemplary embodiment will be further described. The cast seat back frame 1 7 is shown to include a pawl 1 8 and a sector 22. The pawl 1 8 is mounted to the cast seat back frame 1 7 with a fastening device 20 (e.g., a bolt, rivet, etc.) to pivot around the fastening device 20 so that pawl teeth 21 of the pawl 1 8 may be adjusted to interface (e.g., engage and disengage) with the sector 22 so that seat back frame 1 7 may be adjusted. The sector 22 is comprised of a circular ring that is cast directly or integral with the seat back frame 1 7. According to a particularly preferred embodiment, seat back frame 1 7 is preferably made of magnesium. According to alternative embodiments, the seat back frame could also be made of any of a variety of other materials possessing the desired forming characteristics (e.g., aluminum or zinc alloys, etc.). According to a particularly preferred embodiment, the sector 22 is cast from the same metal as the seat back frame 1 7. According to an alternative embodiment, sector 22 is made from another material and insert molded into the seat back frame 1 7 casting or made from another material and mechanically attached to the back frame such as welding, bolting, riveting, etc. The sector 22 includes sector gear teeth 23 which are also cast directly into the seat back frame 1 7 to reduce the number of parts comprising the recliner mechanism. Sector 22 pivots about its own center 24 and is secured by a sector key 25.

[0029] According to another exemplary embodiment shown in FIGURE 4, a recliner mechanism 29 includes a rack 28 with gear teeth 30, and a pinion gear 34. Rotation of pinion gear 34 rotated permits the cast seat back frame 1 7 to pivot arcuately about a pivot point 36 in an arc consistent with aperture 32. In this embodiment, the rack 28 is an integral part of the cast seat back frame 1 7. According to a preferred embodiment, gear teeth 30 and the rack 28 and are integrally cast with seat back frame 1 7. According to particularly preferred embodiment, the rack 28 is cast from the same metal as the seat back frame 1 7. According to an alternative embodiment, rack 28 is made from another material and insert molded into the seat back frame 1 7 casting or made from another material and mechanically attached to the back frame such as bolting or riveting.

[0030] According to another exemplary embodiment, shown in FIGURE 5, a recliner mechanism 37 includes a socket joint 38 integrally cast with the cast seat back frame 1 7. A ball 40 fits within the socket 38 to complete a ball and socket joint and a rod 44 is connected to the ball 40 to allow the ball 40 to be translated in a horizontal direction when the rod 44 is translated in a horizontal direction. This translation permits the adjustment of the seat back frame 1 7 about a pivot point 46. FIGURE 6 shows a finishing cap 47 that is used to cover the various recliner mechanisms.

[0031 ] According to a preferred embodiment shown in FIGURES 7-1 2, a recliner mechanism 49 comprises a hub 48 integrally cast with the seat back frame 1 7, an adjustment plate 58, pawls 54, and a ring sector 64. Hub 48 includes raised portions 76 (defining a space 78), and apertures 80 emanating from a hub center hole 82. Pawls 54 are disposed in space 78 between adjacent raised portions 76. Pins 56 of pawls 54 extend through apertures 80 to engage adjustment plate 54. As adjustment plate 54 rotates, pins 56 slide radially outward in apertures 60 so that gear teeth 55 may engage ring teeth 66 of ring sector 64. Apertures 50 may be cast or machined into hub 48 and include a wide portion 47 and a slot portion 49.

[0032] Adjustment plate 58 is configured to provide a bearing surface (e.g., a bearing race or the like) at periphery of apertures 80. Gear teeth 55 ends of pawls 54 are disposed in space 78 in hub 48. Pin 56 of pawls 54 are designed to pass through apertures 50 in hub and apertures 60 in adjustment plate 58. Gear teeth 55 of pawls 54 are configured to engage teeth 66 of ring sector 64 to lock the seat back frame 1 7 into place.

[0033] When a handle shaft 70 is rotated about its centerline, apertures 60 of adjustment plate 58 move about a center mounting hole 62. The pawls 54 slide radially in apertures 50 due to rotation of the adjustment plate 58 (which provides a bearing surface at periphery of apertures 60 for pins 56) . The ring sector 64 is fastened to a mounting bracket 68 which is mounted to the seat track (not shown) or seat cushion frame 1 9. According to an alternative embodiment, the hub 48 may be cast from the same metal as the seat back frame 1 7, or made from another material and insert molded into the seat back frame casting or made from another material and mechanically attached to the back frame such as bolting or riveting.

[0034] FIGURES 1 3A and 1 3B illustrate alternative ways of rotating adjustment plate 58. Referring to FIGURE 1 3A a manual recliner function may be provided by attaching a cable 84 to an actuator 85 and to the outside diameter of adjustment plate 58, as well as a return spring 86 if needed. Alternatively, referring to FIGURE 1 3B, the recliner could be made to have a motorized release by using a geared motor 88 to rotate adjustment plate 58 causing release or locking of the recliner.

[0035] It is also important to note that the construction and arrangement of the elements of the recliner mechanism as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the recliner mechanism may be any of a variety of mechanism configured to recline a seat. Also, the seat may be mounted in any of a variety of vehicles (e.g., cars, trains, airplanes, etc.) . Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims.

Claims

CLAIMSWhat is claimed is:

1 . A seat for an automobile, comprising: a seat cushion frame; and a seat back frame pivotably coupled to said seat cushion frame, said seat back frame having an integrally cast reclining mechanism, wherein said seat back frame is operable to be adjusted relative to said seat cushion frame with said integral recliner mechanism.

2. The seat of Claim 1 wherein said integral recliner mechanism is a circular sector gear integrally cast into said one of cast seat back frame and that interfaces with a pawl to provide a plurality of seat positions.

3. The seat of Claim 1 wherein said integral recliner mechanism is a circular sector gear integrally coupled to one of said seat cushion frame and said seat back frame that interfaces with a pawl to provide a plurality of seat positions.

4. The seat of Claim 1 wherein said integral recliner mechanism is an arcuate rack gear which interfaces with a pinion gear to provide a plurality of seat positions.

5. The seat of Claim 1 wherein said integral recliner mechanism is a socket which interfaces with a ball to form a ball and socket joint to provide a plurality of positions of the cast seat back frame.

6. The seat of Claim 5 wherein said ball is connected to a rod which is translated to change the position of said ball and socket joint and thus provide a plurality of positions of the cast seat back frame.

7. The seat of Claim 6 further comprising a cap to conceal said cast recliner mechanism and hold the ball in position.

8. The seat of Claim 1 further comprising a hub having a plurality of apertures.

9. The seat of Claim 8 further comprising an adjustment plate having a plurality of apertures equal in number to said apertures in said hub.

1 0. The seat of Claim 9 further comprising a plurality of pawls slidably connected to said adjustment plate.

1 1 . The seat of Claim 1 0 further comprising a ring sector to engage said pawls.

1 2. The seat of Claim 1 1 further comprising a bracket to which said ring sector is fixedly attached.

1 3. The seat of Claim 1 2 further comprising a recliner handle shaft that passes through said hub, said ring sector, and said bracket.

1 4. The seat of Claim 1 wherein the material of said cast seat back frame is magnesium.

1 5. A seat for a vehicle comprising: a seat back frame; a seat cushion frame pivotally coupled to seat back frame; and a recliner mechanism configured to provide adjustment to said seat back frame, said recliner mechanism including an integrally cast portion configured to provide a load path for force to travel through the cast seat back frame and said mechanism and into the vehicle floor upon a force being applied to the rear of the vehicle in which said recliner vehicle is installed.

1 6. The seat of Claim 1 5 wherein said mechanism for adjusting said cast seat back frame further comprises a circular sector to interface with a pawl to achieve various seat positions.

1 7. The seat of Claim 1 5 further comprising a plurality of pawls slidably connected to said adjustment plate.

1 8. The seat of Claim 1 7 further comprising a ring sector, said ring sector having interior gear teeth for engaging said pawls.

1 9. The seat of Claim 1 8 further comprising a recliner handle shaft attached to said adjustment plate and passing through said hub and said ring sector.

20. The seat of Claim 1 5 wherein the material of said cast seat back frame and said mechanism is magnesium.

21 . The seat of Claim 1 5 wherein the recliner mechanism includes a hub having a raised portion defining a space, one or more pawls disposed in the space, a ring sector configured to coact with the pawls, and an adjustment plate configured to move the pawls between an engaged position and a disengaged position.

22. The seat of Claim 21 wherein said hub includes one or more apertures and each pawl includes a pin extending through one of said aperture.

23. The seat of Claim 27 further comprising an adjustment plate having one or more slots which correspond to said apertures in said hub.

24. The seat of Claim 1 5 wherein said integrally cast portion is a circular sector gear provided on seat back frame and configured to interface with a pawl to provide a plurality of seat positions.

25. The seat of Claim 1 5 wherein said integrally cast portion is an arcuate rack gear configured to interface with a pinion gear to provide a plurality of seat positions.

26. The seat of Claim 1 5 wherein said integrally cast portion defines a socket configured to interface with a ball to form a ball and socket joint to provide a plurality of positions of the seat back frame.

27. The seat of Claim 26 wherein said ball is connected to a rod which is translated to change the position of said ball and socket joint and thus provide a plurality of positions of the cast seat back frame.

28. The seat of Claim 27 further comprising a cap to conceal said cast recliner mechanism and hold the ball in position.

29. The seat of Claim 21 wherein the pawl is slidably coupled to said adjustment plate.

30. The seat of Claim 21 further comprising a bracket to which said ring sector is fixedly attached.

31 . The seat of Claim 30 further comprising a recliner handle shaft that passes through said hub, said ring sector, and said bracket.

32. The seat of Claim 1 5 wherein the integrally cast portion is provided on the seat back frame.

33. A recliner mechanism for a seat mounted to a floor, the seat having a seat back frame and a seat cushion frame pivotally coupled to seat back frame, the seat recliner comprising: an integrally cast hub adapted to be provided on said seat back frame, said integrally cast hub having a raised portion defining a space, one or more pawls disposed in the space; a ring sector configured to coact with the one or more pawls; and an adjustment plate configured to move the pawls between a engaged position and a disengaged position.

34. The recliner mechanism of Claim 33 wherein the integrally cast hub is configured to provide a load path for force to travel through the seat back frame and said mechanism and into the floor upon a force being applied from a rearward direction in which said mechanism is installed.

35. The recliner mechanism of Claim 34 wherein said hub includes one or more apertures and each pawl includes a pin extending through one of said aperture.

36. The recliner mechanism of Claim 35 further comprising an adjustment plate having one or more slots which correspond to said apertures in said hub.

37. The recliner mechanism of Claim 36 wherein the pawl is slidably coupled to said adjustment plate.

38. The recliner mechanism of Claim 39 further comprising a bracket to which said ring sector is fixedly attached.

39. The recliner mechanism of Claim 38 further comprising a recliner handle shaft that passes through said hub, said ring sector, and said bracket.

40. The recliner mechanism of Claim 33 wherein the material of said cast seat back frame is magnesium.