Air-suspended seat surfaces for folding vehicle seats

A vehicle seat includes a seatback having a coverstock defining a seat surface with a flexible lower region and a flexible upper region. The seatback further has a compressible upper bladder beneath the coverstock upper region and a compressible inflation bladder positioned beneath the coverstock lower region and in fluidic communication with the upper bladder. A first fixed quantity of a flowable medium is contained in and is partially transferrable between the upper bladder and the inflation bladder.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle seat having compressible portions to facilitate folding of the seat. The compressible portions can be inflated into extended positions during use of the seat.

BACKGROUND OF THE INVENTION

Vehicles may include foldable seats in which a seatback thereof can be rotated in a downward direction into contact with a corresponding cushion. Folding seats can be used in connection with, for example, the rear seats of a vehicle such that the seatbacks thereof can be folded, when not occupied by a passenger or the like, to expand the cargo area provided by the trunk of the vehicle. Accordingly, the degree to which the seatback can be folded impacts the useable cargo area achieved by such folding. Due to ergonomic and other concerns, seatbacks and cushions may have contours and thicknesses that limit the folding of the seatback such that a rear surface of the seatback, on which cargo is supported, is angled significantly upward from the adjacent trunk surface. This can impact both the useable cargo space, as well as the ability to reliably place objects on the sloped surface. Accordingly, improvements to vehicle seats are desired that allow for a greater degree of folding.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a vehicle seat includes a seatback having a coverstock defining a seat surface with a flexible lower region and a flexible upper region. The seatback further has a compressible upper bladder beneath the coverstock upper region and a compressible inflation bladder positioned beneath the coverstock lower region and in fluidic communication with the upper bladder. A first fixed quantity of a flowable medium is contained in and is partially transferrable between the upper bladder and the inflation bladder.

According to another aspect of the present invention, a seatback for a vehicle seat includes a coverstock defining a seatback surface with a flexible lower region and a flexible upper region. The seatback further includes a compressible upper bladder beneath the coverstock upper region and a compressible inflation bladder underlying the coverstock lower region and in fluidic communication with the upper bladder. A fixed quantity of a flowable medium is contained in and is partially transferrable between the upper bladder and the inflation bladder.

According to another aspect of the present invention, a vehicle seat includes a seatback having an upper bladder within an upper region thereof and a first inflation bladder within the seatback remote from the upper region. The seat further includes a cushion with which the seatback is rotatably coupled. The first inflation bladder is in communication with the upper bladder and defines a first closed unit therewith containing a first fixed quantity of a flowable medium.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “interior,” “exterior,” and derivatives thereof shall relate to the invention as oriented inFIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawing, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Additionally, unless otherwise specified, it is to be understood that discussion of a particular feature of component extending in or along a given direction or the like does not mean that the feature or component follows a straight line or axis in such a direction or that it only extends in such direction or on such a plane without other directional components or deviations, unless otherwise specified.

Referring toFIG. 1, reference numeral10generally designates a vehicle seat. Vehicle seat10includes a cushion12having a cushion coverstock14defining a seat surface16with a flexible central region18and a flexible edge region20. A compressible edge bladder22is located beneath the edge region20of cushion coverstock14and a first compressible inflation bladder24is positioned beneath central region18of coverstock14and is in fluidic communication with the edge bladder22(such as by connection therewith by a cushion tube26). A first fixed quantity of a flowable medium28(such as air or other various inert, non-reactive gasses or mixtures thereof) is contained in and is partially transferrable between the edge bladder22and the inflation bladder24.

As shown inFIGS. 1-3, vehicle seat10can include a seatback30that can be rotatably coupled with cushion12such that seatback30can be configured in an open position wherein the seatback30is away from edge region20(as shown inFIG. 1) and a folded, or closed, position (as shown inFIG. 2), wherein a portion of seatback30is in contact with edge region20. In general, the structure of vehicle seat10may be similar to that which may be typically found in connection with the rear seats of a vehicle, whereby the folding provided by vehicle seat10(as shown inFIG. 2) can be used to increase the cargo capacity of an adjacent trunk of the associated vehicle. Such a folding configuration can also be used in one or more of the front seats32of the associated vehicle, such as the passenger-side front seat32. Accordingly, the various features of vehicle seat10discussed herein may be particularly described with reference to a vehicle seat10positioned toward the rear of the associated vehicle, and maybe implemented in connection with, for example, a rear bench-style seat (such as a 60/40 split-folding rear bench), rear captain-style seats, or the like. Such features, however, may also be usable in connection with a front passenger seat32.

With continued reference toFIGS. 1-3, the incorporation of inflation bladder24and edge bladder22connected, for example, by tube26(which couples with edge bladder22and inflation bladder24on opposite ends thereof), can provide for an alteration of the profile of cushion12when seat10is unoccupied such that an angle36of rear seat surface34with respect to trunk floor38of about 6°, or less can be achieved. Further, such features may allow cushion12to provide a comfortable and safe contour for an occupant ο when seated thereon, as shown inFIG. 3. In particular, the various features of cushion12provide for such variation in the contour of seat surface16by facilitating transfer of flowable medium28between inflation bladder24and edge bladder22under various circumstances. In particular, both edge bladder22and inflation bladder24can both be generally compressible and/or flexible such that they can be compressed or expanded by variation in pressure either interior or exterior thereof.

Edge bladder22, inflation bladder24, and tube26can be of a generally air-impermeable material, such as plastic or the like such that the edge bladder22, inflation bladder24, and tube26define a closed unit or system containing a fixed quantity of flowable medium28therein. In an example, edge bladder22and inflation bladder24can be configured to contain the flowable medium28at a pressure of up to about 3 pounds per square inch gauge (“p.s.i.g.”), but can be inflated with flowable medium28to between about one-third and one-half of such maximum pressure, or between about 0.5 p.s.i.g. and 1.0 p.s.i.g. Accordingly, an increase in external pressure over one of either edge bladder22or inflation bladder24can cause at least a portion of the flowable medium28within such structure to transfer and increase the interior pressure of such flowable medium28within the other of such structures. In this manner, the pressure of flowable medium28within the closed structure of edge bladder22, inflation bladder24, and tube26can reach a consistent, equilibrium pressure within such unit.

The above-described transfer of flowable medium28between edge bladder22and inflation bladder24by pressure applied to inflation bladder24may result in compression of inflation bladder24and a corresponding inflation, or at least an increase of the pressure of flowable medium28therein, of edge bladder22(so long as any external pressure applied to edge bladder22is less than the pressure by which inflation bladder24is compressed). As shown inFIG. 3, this transfer is carried out when an occupant ο is seated on the vehicle seat10, wherein a majority of the weight of occupant ο is centered over central region18of seat surface16and, accordingly on inflation bladder24, which is positioned therebeneath. The weight of occupant ο on inflation bladder24applies pressure thereon, thereby transferring an amount of the flowable medium28to edge bladder22, which causes edge bladder22to inflate or expand under pressure, thereby providing a retention, or supporting, force to support edge region20of seat surface16above an underlying portion46, of floor pan48in a generally elevated position sufficient to maintain edge region20in contact with portions of occupant ο thereover (at least when occupant ο is in a neutral seated position).

As shown inFIG. 1, where no occupant ο is seated in vehicle seat10, edge bladder22and inflation bladder24may be in a generally neutral state, which may at least be partially dictated by the natural position of seat surface16, as dictated by coverstock14. In general, coverstock14may be comprised of various layers of foam and fabric or leather and may result in a flexible structure such that the various portions thereof are moveable by, for example, a force applied thereto causing compression of the underlying structure (including edge bladder22and inflation bladder24) or by expansion of either of edge bladder22or inflation bladder24, as discussed further below. When seatback30is rotated into a folder position, as shown inFIG. 2, a portion of seatback30may be brought into contact with edge region20of cushion12. A force applied to seatback30, when positioned as such, may increase the pressure of the flowable medium28within edge bladder22, thereby compression edge bladder22by movement of the edge region20of coverstock14into a compressed position (FIG. 2), thereby correspondingly increasing the pressure of the flowable medium28within inflation bladder24and allowing seatback30to fold to a generally flatter position (i.e. of a higher angle36) then would be possible without the compression of edge region20.

As shown inFIGS. 5 and 6, the above-described compression of edge bladder22can allow for a change (and/or thickness) of edge bladder22. As shown inFIG. 5, when edge bladder22is in an inflated state, edge bladder22may have a height41that generally corresponds to the elevated position of edge region20of seat surface16(FIG. 3). Upon compression of edge bladder22, as shown inFIG. 6, edge bladder22may have a height43that is less than height41thereof in the inflated state, and which may correspond to the position of edge region20of seat surface16when in the compressed position (FIG. 2). In an example, edge bladder22may be configured such that height43is less than height41by at least about 20 mm, and in one example between about 30 mm and 40 mm, thereby facilitating similar compression of edge region20of cushion12. In an example, height43of edge bladder22in the compressed position may be about 20.0 mm. Further, compression of edge bladder22may not be evenly-distributed in a direction from the front of cushion12to the rear thereof, the compression thereof being measured in such an example by a portion thereof that exhibits the greatest degree of compression.

As further illustrated inFIGS. 5 and 6, edge bladder22may define a plurality of fixed cells44which may substitute for all or a portion of any foam which may otherwise be present in coverstock14at least in the area of edge bladder22. As illustrated, such fixed cells44do not appreciably expel any air or other medium contained therein during compression of edge bladder22. Further, cells similar to fixed cells44may be present along a portion of inflation bladder24and/or along an entirety of seat surface16and also within seatback30.

Returning now toFIGS. 1-3, vehicle seat10can include an additional bladder in the form of an upper bladder50within a flexible upper region52of seatback30. As illustrated, in an embodiment upper bladder50can be connected with inflation bladder24by a seatback tube54. In this manner, seatback tube54and upper bladder50can be included in the closed unit described above as including edge bladder22, inflation bladder24, and cushion tube26. As such, upper bladder50can be of the same or similar material to edge bladder22and inflation bladder24so as to be generally compressible by resilient deformation thereof under pressure and may further be generally air impermeable such that the fixed quantity of flowable medium28can further be contained in upper bladder50and transferrable at least in part, between inflation bladder24and upper bladder50by seatback tube54.

In a manner similar to edge bladder22, described above, upper bladder50can support a portion of seatback coverstock56within upper region52thereof when upper bladder50is in an inflated or expanded state due to pressure on inflation bladder24, such as by the weight of occupant ο, as shown inFIG. 3. Further, a portion of flowable medium28can be expelled from upper bladder50and into inflation bladder24due to pressure applied to upper region52, such as by forceable movement of seatback30into the folded position shown inFIG. 2. Such compression can allow for a decrease in thickness of seatback30adjacent upper region52by movement of seatback coverstock56within upper region52between an extended position and an inward position wherein a thickness of seatback30is greater when coverstock56is in the extended position (thickness62inFIG. 1) within upper region52than when in the compressed position (thickness64inFIG. 3). Such compressibility may further add to the ability of vehicle seat10to fold into a relatively flatter position. In such an embodiment, inflation bladder24can be sized to receive portions of flowable medium28from both upper bladder50and edge bladder22when both are in the compressed state.

In another example of a vehicle seat110shown inFIG. 7, vehicle seat110includes an inflatable and compressible edge bladder122as well as an inflatable and compressible upper bladder150and can, further, include a plurality of inflation bladders124a,124b, and124c. In the example shown, a central one of the inflation bladders124bcan be connected with upper bladder150by seatback tube154such that compression of inflation bladder124bcauses inflation and/or expansion of upper bladder150, and compression of upper bladder150is permitted absent a greater compressive force on inflation bladder124b. Further, a corresponding pair of inflation bladders124aand124c, positioned laterally outside of and surrounding inflation bladder124bon opposing sides thereof, are connected with edge bladder122by cushion tube126having a plurality of a branch166fluidically coupled with inflation bladder126c. In this configuration, a pressure evenly distributed along central region18of seat surface16can provide for a greater quantity of air flow, and accordingly, a greater amount of pressure increase within edge bladder122, as compared to upper bladder150. Such as pressure differential may be advantageous, as the weight applied over edge region120may be greater than that applied on upper region152when an occupant is seated in vehicle seat110.

As shown inFIGS. 8-11, vehicle seat110may be specifically configured to retain inflation bladders124in a desired position within cushion112. As such, cushion112may include a lower tray168configured for supporting inflation bladders124a,124b, and124cand a cover foam unit170shaped to extend over and separate inflation bladders124a,124b, and124c. Further, cover foam170may include a plurality of grooves174sized to receive therein corresponding ridges172a,172b, and172ccoupled with and extending from inflation bladders124a,124b, and124c, respectively. Ridges172can be integrally formed with inflation bladders124a,124b, and124c, such as by heat-sealing of excess material thereof by a distance corresponding to a desired height of ridges172a,172b, and172c. Accordingly, when cover foam unit170is assembled over inflation bladders124a,124b, and124c, ridges172a,172b, and172ccan be received in corresponding grooves174a,174b, and174c, thereby helping to retain the desired position of inflation bladders124a,124b, and124c, such as by prevention of rotation or twisting thereof. Such a configuration may be particularly useful in preventing such movement of inflation bladders124a,124b, and124cduring compression, such as by the weight of occupant ο on cushion12, as shown inFIG. 9.

As shown inFIG. 10, tray168may include additional ridges176extending therealong that correspond to grooves178formed in a portion of cover foam170. Engagement of ridges76with grooves78facilitating coupling of cover foam170with tray168, which may help to retain inflation bladders124a,124b, and124cwithin cushion12. To further facilitate retention of ridges172and/or ridges76within corresponding grooves174and178a plurality of resiliently deformable fins180may be coupled within grooves174and178, such fins180extending toward a center of the corresponding grooves174or180and generally angling in a direction of insertion of the corresponding ridges176and172, thereby allowing insertion thereof, but generally restricting withdrawal.

As shown inFIG. 12in a variation, vehicle seat210can include a plurality of inflation bladders224a,224b, and224cthat extend laterally with respect to cushion212(i.e. in a direction in and out of the page with respect toFIG. 12). Further, vehicle seat210can include a plurality of edge bladders222aand222b, as well as a plurality of upper bladders250aand250b, all extending laterally with respect to edge region220and upper region252, respectively. In such an arrangement, inflation bladder224bcan be connected by a tube (not shown) with both upper bladders250aand250b. Further, both of inflation bladders224aand224ccan be fluidically coupled by a tube (not shown) with both edge bladders222aand222b. Alternatively, inflation bladder224acan be fluidically coupled with edge bladder222band inflation bladder224ccan be fluidically coupled with edge bladder222a, with other such combinations also being contemplated.

As shown inFIGS. 13-15, in a variation of vehicle seat310edge bladder322and inflation bladder324can be configured to extend substantially throughout the entirety of seat surface316, including in a fore-aft direction within the associated vehicle. In such a configuration, edge bladder322can be configured to partially overlap with inflation bladder324in a vertical direction384. The extension of edge bladder322and inflation bladder324throughout the entirety of seat surface316may help to provide reliable compression of inflation bladder324by an occupant ο seated in vehicle seat310, including by accommodating for various seating positions of occupant ο with respect to vehicle seat310. Further, the overlap between edge bladder322and inflation bladder324may help provide a generally smooth transition between such components when an occupant ο is seated in vehicle seat310, as shown inFIG. 15.

As shown inFIG. 13, vehicle seat310may function in a similar manner to other embodiments of vehicle seats discussed herein, including by allowing deflation of edge bladder322under pressure from a downwardly-folded seatback330against edge region320of cushion312, including transfer of a portion of the flowable medium328from edge bladder322to inflation bladder324. As shown inFIG. 14, absent any external pressure on seat surface316, that natural shape of coverstock314may cause edge bladder322and inflation bladder324to be configured in a general neutral position, including positioning of edge region320in an elevated position. As shown inFIG. 15, pressure on inflation bladder324by the weight of an occupant ο thereon, for example, may cause a transfer of flowable medium328from inflation bladder324into edge bladder322, thereby providing an expansion force within edge bladder322sufficient to urge edge region320into the extended position and/or to maintain edge region320in such a position under the weight of the legs, for example, of occupant ο thereon.

In an further variation of vehicle seat310, shown inFIGS. 13-15, edge bladder322and inflation bladder324may be formed in a single bladder unit, such as by being formed in a unitary structure such as a larger bladder unit with division therebetween along the area of overlap81between the portion thereof designated as edge bladder322and the portion thereof designated as inflation bladder324. In such a manner, inflation bladder324and edge bladder322may be in fluidic communication by one or more gaps (not shown) in a seam or other structure separating edge bladder322from inflation bladder324.

Turning now toFIGS. 16-18, a further variation of vehicle seat410is shown, in which seatback430includes an upper bladder450positioned beneath an upper region452of seatback coverstock456. Upper bladder450is of a similar construction to, for example, upper bladder450described above with respect toFIGS. 1-3and is further compressible by expulsion of a portion of a flowable medium428contained therein under a pressure applied thereto and inflatable by transfer of a further portion of a flowable medium428thereinto. As illustrated, seatback430further includes a seatback inflation bladder486positioned therein and underlying a lower region458of seatback coverstock456that corresponds, for example, to the general area of seatback430that provides lumbar support for an occupant. Accordingly, a second fixed quantity of flowable medium428is contained within the closed unit formed by seatback inflation bladder486, upper bladder450and seatback tube454, which fluidically connects upper bladder450with seatback inflation bladder486,

As shown inFIG. 17, seatback inflation bladder486is compressible under the weight of a portion of occupant ο (e.g. the lower back region) when seated in vehicle seat410. Such compression of seatback inflation bladder486causes a portion of the fixed quantity of the flowable medium428into upper bladder450, thereby increasing the pressure of the flowable medium428within upper bladder450and providing a corresponding force therein to retain the upper region452in an extended position (as shown inFIGS. 17) to maintain upper region452of seatback coverstock456in general contact with an adjacent portion of occupant ο. The pressure of the flowable medium428within seatback inflation bladder486, upper bladder450, and seatback tube454can be in the same general range of pressure for flowable medium28described above with respect toFIGS. 1-3.

With further reference toFIGS. 16 and 17, lower region460of seatback coverstock456can be generally flexible between an extended position (FIG. 16) and a compressed position (FIG. 17), with the extended position inFIG. 17generally corresponding to a typical contour of a comparable region in an ordinary vehicle seatback for the support of an occupant's lumbar back area, with the compressed position shown inFIG. 16flexing inwardly from the remaining portions of seatback coverstock456by an amount approximately equal to that would be ordinarily observed in a vehicle seat under the pressure of the back of an occupant. This configuration results inward flexing of lower region by occupant ο in an ordinary seated position so as to move inflation bladder486into the compressed state shown inFIG. 17.

As shown inFIG. 18, when seatback inflation bladder486is in a neutral state, such as when not being compressed by the weight of an occupant in vehicle seat410, upper bladder450is compressible so as to permit movement of the upper region452of seatback coverstock456to be moved into the corresponding compressed position, such as under forcible movement of seatback430into the folded position shown inFIG. 18, wherein edge region420of cushion412is pressed into upper region452of seatback coverstock456. Such compression of upper region452and of upper bladder450can be generally similar to the compression thereof described above with respect toFIGS. 1-3.

In various embodiments of a vehicle seat410including a seatback430, as described above, and further including seatback inflation bladder486fluidically coupled with upper bladder450, the corresponding cushion412can itself include an inflation bladder424fluidically coupled with an edge bladder422in a similar manner to the various embodiments discussed above with respect toFIGS. 1-16. In such embodiments, inflation bladder424can be fluidically coupled with edge bladder422only and not with upper bladder450. Further, various alternative embodiments of a seatback including an upper bladder coupled with a seatback inflation bladder can be similar to the various alternative embodiments of inflation bladder124, inflation bladder224, or inflation bladder324, and corresponding variations of the edge bladder122,222, and322, described above with respect toFIGS. 4-6,FIGS. 7-11,FIG. 12, andFIGS. 13-15.