Abstract:
Adaptors are disclosed for a seat assembly. The adaptors may be used for mounting a support extending substantially across a frame between first and second side members. The adaptor may be attachable to an opening in the frame. The support may include a hook having a bending distal end. The adaptor includes a non-metal body including a mounting structure configured for attaching the body to the opening in the frame, a passageway extending through the body for receiving the hook, and a seat within the body for securing the bending distal end of the hook to the adaptor. The mounting structure is configured so that when the support is loaded the adaptor is loaded by the hook substantially in compression. Alternatively, other designs with the loading in compression or tension are possible whereby the adaptor includes other combinations of features. Seat assemblies are also disclosed. The support may be a seat back or bottom, or a lumbar support. Methods of assembly are also disclosed.

Description:
FIELD OF INVENTION  
       [0001]     The present invention relates generally to various designs for mounting adaptors for seat assemblies and seat assemblies using particular mounting adaptor designs. The adaptors may be used with any manner of seats and supports, such as seat back or base supports, or lumbar supports, and the like.  
       BACKGROUND OF INVENTION  
       [0002]     Seats such as vehicle seats may be constructed using a rigid internal frame having a support extending across portions of the frame. The supports may comprise metal members such as rods, coils, bars, straps, or the like. Examples of seat support configurations are shown in U.S. Pat. Nos. 4,880,271; 5,911,477; 6,152,531; 6,595,585; and Application No. U.S. 2003/0227203. Padding is placed over the supports and frames for comfort. The supports include back and bottom supports, as well as lumbar supports, which may be adjustable.  
         [0003]     The devices disclosed in the above patent publications suffer from various drawbacks. Often, supports and frames are both made of metal, at least at the points of contact. For example, metal support hooks may extend into openings in or tabs extending from the frame. Such metal-to-metal contact between supports and framework can cause “BSR” issues (noise comprising buzz, squeak, and/or rattle). Also the ends of supports may come loose if they traverse too far in an outward direction, thereby detaching the seat supports. Connecting the supports and frames more securely adds complicated steps to assembly and/or additional parts.  
         [0004]     Other designs have been proposed, for example where a plastic “omega-shaped” mounting element is attached to a frame, with the loop of the omega pointing inward. Such plastic element therefore can replace a somewhat similarly shaped tab (such as Tab 5A shown in U.S. Pat. No. 6,152,531) to provide a quieter assembly. However, the omega-shaped element still suffers the drawback of allowing the ends of supports to be moved laterally outward of the loop. Further, this design loads the loop in tension, which can in some circumstances cause failure in plastic elements.  
       SUMMARY  
       [0005]     Accordingly, it is an object of the invention to provide various adaptor designs, and related seat assembly designs, along with related methods of assembly, all of which will provide simple structure, reliable use, and ease of assembly, overcoming one or more of the above or other drawbacks found in conventional devices.  
         [0006]     According to certain aspects of the invention, a disclosed seat assembly includes a frame having a first side member and a second side member, a support attached to and extending substantially across the frame between the first and second side members, the support including at least one attachment portion, and an adaptor configured for attachment to the frame. The attachment portion of the support is securable to the adaptor thereby attaching the support to the frame, the attachment portion and adaptor configured so that loading of the support causes the attachment portion to load the adaptor substantially in compression. Various options and modifications are possible.  
         [0007]     For example, the frame and attachment portion may be made of metal and the adaptor made of a non-metal. The non-metal may be one of a plastic, a silicone, or an elastomer. If desired, the attachment portion may be formed as a hook, and the adaptor may include a base for receiving the hook. The adaptor may also include a passageway adjacent the base for guiding the attachment portion to the base, or the adaptor may include a hood adjacent the base for precluding movement of the hook in an outward direction relative to the frame. The hook may include a bending distal end, the adaptor configured so that the bending distal end is disposed substantially outside the frame.  
         [0008]     If desired, the attachment portion and adaptor may be configured so as to substantially limit translational sliding of the attachment portion relative to the adaptor. Also, the attachment portion and adaptor may be configured so that an extending area of contact exists between the adaptor and the attachment portion. The adaptor may be configured for receiving the attachment portion so that the attachment portion may travel substantially in only one plane relative to the adaptor. The adaptor and frame may be configured so that the adaptor snaps into place within the frame, and the adaptor may include at least one flange for seating against an outer portion of the frame.  
         [0009]     If desired, the support may be a lumbar support. If so, an adjustment mechanism may be mounted to the frame for moving the lumbar support relative to the frame. The lumbar support may include at least one spring member, the attachment portion extending from an end of the spring member. Alternatively, the support may be one of a seat back or bottom having a plurality of the attachment portions, and a plurality of the adaptors are provided, each adaptor for securing one of the attachment portions to the frame.  
         [0010]     According to other aspects of the invention, a lumbar support seat assembly includes a frame having a first side member and a second side member, a lumbar support assembly attached to and extending substantially across the frame between the first and second side members, the lumbar support assembly including two attachment portions, and two adaptors configured for attachment to the frame. One adaptor is attached to the first side member and the other adaptor being attached to the second side member. Each attachment portion of the lumbar support assembly is securable to a respective one of the adaptors thereby attaching the lumbar support assembly to the frame, the attachment portion and adaptors configured so that loading of the lumbar support assembly causes the attachment portion to load the adaptors substantially in compression. As above, various options and modifications are possible.  
         [0011]     According to other aspects of the invention, an adaptor for a seat assembly is disclosed, the adaptor for mounting a support extending substantially across a frame between first and second side members, the adaptor attachable to an opening in the frame, the support including a hook having a bending distal end. The adaptor includes a non-metal body including a mounting structure configured for attaching the body to the opening in the frame, a passageway extending through the body for receiving the hook, a base within the body for securing the bending distal end of the hook to the adaptor, and the mounting structure configured so that when the support is loaded the adaptor is loaded by the hook substantially in compression. As above, various options and modifications are possible.  
         [0012]     According to still other aspects of the invention, a seat assembly includes a frame having a first side member and a second side member, a support attached to and extending substantially across the frame between the first and second side members, the support including at least one hook-shaped attachment portion having a distal end, and an adaptor configured for attachment to the frame. The attachment portion of the support is securable to the adaptor thereby attaching the support to the frame, the adaptor defining a passageway for receiving the attachment portion, a base for seating the distal end, and a hood for precluding movement of the attachment portion in an outward direction relative to the frame. Again, various modifications and options are possible.  
         [0013]     According to other aspects of the invention, a lumbar support seat assembly includes a frame having a first side member and a second side member, a lumbar support assembly attached to and extending substantially across the frame between the first and second side members, the lumbar support assembly including two hook-shaped attachment portions each having a distal end, and two adaptors configured for attachment to the frame. One adaptor is attached to the first side member and the other adaptor being attached to the second side member, each attachment portion of the lumbar support assembly being securable to a respective one of the adaptors thereby attaching the lumbar support assembly to the frame, the adaptors each defining a passageway for receiving a respective attachment portion, and a base for seating a respective distal end. A hood precludes the movement of the respective attachment portion in an outward direction relative to the frame. As above, various options and modifications are possible.  
         [0014]     According to still other aspects of the invention, an adaptor is disclosed for a seat assembly, the adaptor for mounting a support extending substantially across a frame between first and second side members, the adaptor attachable to an opening in the frame, the support including a hook having a bending distal end. The adaptor includes a body including a mounting structure configured for attaching the body to the opening in the frame, a passageway extending through the body for receiving the hook, a base within the body for securing the bending distal end of the hook to the adaptor, and a hood for precluding movement of the distal end in an outward direction relative to the frame. As above, various options and modifications are also possible within the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     The above and other aspects and advantages of the present invention are apparent from the detailed description below and in combination with the drawings in which:  
         [0016]      FIG. 1  is a perspective representation of a seat assembly showing various options for mounting different types of supports according to certain aspects of the present invention.  
         [0017]      FIG. 2  is a perspective view taken along line  2 - 2  in  FIG. 1  showing mounting of a lumbar support using adaptors according to certain aspects of the present invention.  
         [0018]      FIG. 3  is an enlarged partial sectional view of a portion of  FIG. 2  noted by reference numeral  3 .  
         [0019]      FIG. 4  is a front view of a portion of the seat of  FIG. 2 , as viewed from line  4 - 4 .  
         [0020]      FIG. 5  is a perspective view of a portion of the seat of  FIG. 2  as viewed from line  5 - 5 .  
         [0021]      FIG. 6  is an end view of an adaptor according to certain aspects of the present invention.  
         [0022]      FIG. 7  is a side view of the adaptor of  FIG. 6 .  
         [0023]      FIG. 8  is a perspective view of the adaptor of  FIG. 6 . 
     
    
     DETAILED DESCRIPTION  
       [0024]     Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the figures. Each embodiment is presented for purposes of explaining the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a different embodiment. It is intended that the invention include these and other modifications and variations as come within the scope and spirit of the invention.  
         [0025]      FIGS. 1 and 2  broadly show in diagrammatic form a seat assembly  10  (including seat back portion  10   a  and seat bottom portion  10   b ) according to certain aspects of the present invention. As shown, the seat assembly includes a frame  12 , a number of adaptors  14  and a number of supports  16 ,  18 ,  20 ,  22 ,  24 ,  26 ,  28  and  30 . It should be understood that the present invention is not limited to any particular seat type, nor any support type. Accordingly, the present invention, in its various scopes and combinations, is suitable for use with various types of seats and supports in various ways. The example shown in  FIGS. 1 and 2  is accordingly a demonstrative example only and is not indicative of the full scope of the invention or of any particular limiting embodiment of the invention.  
         [0026]     As shown, supports  18  comprise vertical support members of a seat back support. Supports  18  include spring portions  18   a,  as shown. Support  20  comprises a bar extending across the seat back portion without any spring portion. Supports  22  comprise bars, similar to supports  18  having spring portions  22   a  and extending across a seat back portion. Supports  24  comprise spring members such as sinuous members extending across the entire frame. Supports  26  and  28  comprise bars extending across seat bottom portion  10   b,  and include spring portions  26   a  and  28   a.    
         [0027]     Support  30  comprises a lumbar support assembly. As broadly shown herein, the lumbar support assembly includes a conventional support plate  32 , an adjustment mechanism  34 , a cable such as a Bowden cable  36  connecting the adjustment mechanism with other portions of the lumbar support assembly, such as springs  38 . As is known, rotation of the adjustment assembly causes the adjustment cable to move in a way to move lumbar support plate  32  back and forth within the seat to improve comfort of the user of the seat.  
         [0028]     Adaptors  16  are shown as used with each of the ends of all of the supports shown in  FIGS. 1 and 2 , although it should be understood that, if desired, certain benefits of the invention could be achieved using adaptors on only one of the two ends of the supports. The adaptors are not shown in any detail in  FIG. 1  or  FIG. 2 , only the relative positions are diagrammatically shown therein.  
         [0029]     Typically, frame  12  is comprised substantially of metal members, and supports  18 - 30  also comprise a number of metal members as well. Particularly, the ends of supports  18 - 30  where the supports attach to portions of frame  12  are typically metal, having bending distal ends in the form of a hook or the like. It should be understood that, as shown below, such attachment portion shapes do provide certain benefits, but such shapes are not required for practice of all aspects of the present invention.  
         [0030]      FIG. 3  shows a cross-sectional view of a portion of a possible interface between an adaptor  16 , a support  40  (which could extend from any of adaptors  16 - 30 , above) and a frame  12 . As shown in  FIG. 3 , adaptor  16  is configured for attachment to frame  12 , and attachment portion  42  of support  40  is securable to the adaptor to thereby attach the support to the frame. Accordingly, frame  12  may define an opening  44  into which adaptor  16  may be inserted. If desired, the opening may be non-symmetrically configured to ensure that adaptor  16  is properly inserted into the opening. As shown, a small mounting portion  46  may be formed on adaptor  16  in a shape to conform to opening  44 . If the adaptor is to be inserted so as to stay in one position, such mounting flange could be, for example, D-shaped. However, it is also possible that, once inserted, adaptor  16  be configured to rotate relative to frame  12 . In such situation, mounting portion  46  could instead comprise a circle and frame  12  could therefore define a mating circular opening  44 . Allowing adaptor to pivot slightly relative to frame  12  allows for a further adjustment in movement of support  40  relative to frame, which could be desired in certain applications. Other attachment arrangements, such as bayonet fits, rotational lock fits, keys, sliding lock fits, etc. are also possible.  
         [0031]     As shown in  FIGS. 3 and 6 - 8 , adaptor  16  may include a number of cantilevered arms for snap-fitting adaptor  16  within opening  44 . As shown, three such arms  48  are provided, although other numbers and arrangements are also possible. Also, at least one mounting flange  50  may also be provided on an outside portion of adaptor  16  to seat adaptor  16  in place. Therefore, adaptor  16  is essentially held in place between the snap-fit of arms  48  and mounting flange  50 , as located within opening  44  via mounting portion  46 . Again, adaptor  16  may or may not be movable relative to frame  12  once snapped into place, as desired.  
         [0032]     As shown in  FIG. 3 , adaptor  16  may be configured in a manner such that once attachment portion  44  of support  40  is secured, that loading of the support causes the attachment portion to load the adaptor substantially in compression. Thus, as shown in  FIG. 3 , loading of attachment portion  42  would provide a force directed generally down and to the right loading adaptor  16  in compression. Attachment portion  42  may include a hook portion  52  having a bending distal end  54  that mates with a base  56  of adaptor  16 . Thus, as shown in  FIG. 3 , bending distal end  54  is disposed substantially outside of frame  12  when assembled, and loading of adaptor  16  occurs in areas such as mounting flange  50 , base  56 , etc., substantially in compression. Such loading can be beneficial, for example, if adaptor  16  is made of a non-metal material, such as plastic. The plastic material could be a polyamide such as nylon or a POM such as acetyl, in either case with or without a glass fill. Loading of a non-metal such as a plastic in compression, rather than in tension, provides a more reliable construction in terms of potential for stretching or failure, due to inherent properties of plastics. The adaptor may be injection molded, if desired. Alternatively, the adaptor could be made of an elastomer, such as a rubber or a silicone compound. However, it should be understood that it is not necessary to utilize non-metal for the adaptor to achieve all aspects of the present invention. Use of a non-metal does provide benefits of eliminating BSR type noises by eliminating metal-to-metal contact which can be beneficial.  
         [0033]     Adaptor  16  may also include additional structure for improving the mounting and retaining of attachment portion  42  of support  40  within adaptor  16 . For example, a passageway  58  may be defined through adaptor  16  for guiding attachment portion  42  to base  56 . The passageway may be generally in the form of an open trough or a tunnel, as desired. Also, a hood  60  may be provided at an outer portion of adaptor  16  so as to prevent movement of attachment portion  42  in an outward direction relative to frame  12  once assembled.  
         [0034]     Use of passageway  58  and/or hood  60  improves the security of the attachment between parts without requiring more complex metal work, crimping, clips, etc. Thus, once assembled, attachment portion  42  and adaptor  16  are so configured so as to substantially limit translational sliding of the attachment portion relative to the adaptor in any direction. That is, hood  60  prevents attachment portion  42  from moving outward, base  56  prevents the attachment portion from moving inward or downward (as shown in  FIG. 3 ), and passageway  56  prevents the attachment portion from moving upward (as shown in  FIG. 3 ). Also, the widths of passageway  58  and hood  60  can be defined to be only slightly wider than attachment portion  42  so as to prevent motion of the attachment portion into or out of the plane of  FIG. 3 . Thus, adaptor  16  is configured for receiving attachment portion  42  so that the attachment portion may travel substantially in only one plane relative to the adaptor, that plane being a plane substantially parallel to the section shown in  FIG. 3 . While it should be understood that some play of attachment portion  42  relative to adaptor into or out of the plane is contemplated for purposes of assembly and prevention of binding during use, such motion is substantially precluded if all such structure is utilized. Such structure accordingly provides an additional benefit of providing a secure mounting of attachment portion  42  within adaptor  16  thereby substantially reducing the possibility of disattachment.  
         [0035]     As shown in  FIG. 3 , passageway  58  includes a cutaway portion  62  to allow hook portion of  52  to be inserted into passageway  58  by rotating one part relative to the other during assembly. After assembly, such relative rotation is extremely unlikely during any expected use of the seat, including jolts from accidents or the like, therefore providing a secure attachment that is at the same time relatively simple to assemble.  
         [0036]     As stated above, various options are possible with the adaptor, seat assembly, including a lumbar support assembly, shown herein. For example, it would be possible to reverse mounting flange  50  and arms  48  so that adaptor  16  would snap in from the inside, rather than the outside. Also, it would be possible to change the arrangement of base  56  relative to frame  12  such that base  56  would be loaded in tension, rather than compression.  
         [0037]     It should also be understood that other types of support attachment portions could be utilized while still obtaining certain benefits of the invention. Thus, if desired, any of the supports shown in  FIG. 1  could be slid through an opening similar to hood  60  disposed on an inner surface of a modified adaptor so as to mount the supports in place. Such structure could be particularly useful for sinuous coil-type supports, such as support  24 . In such case, the benefits provided by using the bending distal end of attachment portion  42  might not be achieved in all cases, but the benefits of BSR improvement, snap-in attachment, easy assembly, etc. could still be achieved.  
         [0038]     Accordingly, it should be understood that the above disclosure is an exemplary disclosure of various options, and should not be considered limiting as to the full scope of the invention. It is possible to mix and match different features from the different figures to achieve new or revised embodiments. The true scope and spirit of the present invention is set forth in the appending claims and their equivalents.