Release mechanism for fold and flip seat assembly

A vehicle fold-and-flip seat assembly includes a first track and a second track supported for movement relative to the first track for horizontal seat adjustment. A seat bottom is supported on the second track for movement with the second track and is movable between a horizontal position and a vertical position. A seat back is supported on a pivot bracket mounted to the second track and pivots relative to the seat bottom between an upright position and a folded position. A first lever is rotatably supported on the second track to control the movement of the seat back between the upright and folded positions when selectively actuated by a control assembly. A latch mechanism is used to secure a rear portion of the first track to the vehicle structure and is movable between a latched position and an unlatched position. A second lever is rotatably supported on the second track to control the movement of the latch mechanism between the latched and unlatched positions when selectively actuated by the control assembly such that the seat bottom along with the folded seat back can be flipped from the horizontal position to the vertical position when the latch is in the unlatched position.

BACKGROUND OF THE INVENTION
 This application relates generally to a vehicle seat adjuster assembly for
 a vehicle seat having a seat back that is folded onto a seat bottom where
 the seat back and bottom are flipped upwardly to a stowed position to
 increase the available cargo space in a vehicle. More particularly, this
 invention relates to a seat adjuster assembly with a first lever portion
 that controls seat back pivotal movement and a second lever portion that
 controls a latch mechanism to allow the seat to be folded and flipped to
 the stowed position.
 Seat track and adjuster arrangements for mounting seats within vehicles are
 generally well known. Most arrangements provide for a seat to be moved or
 adjusted in forward and rearward directions within a vehicle.
 In many circumstances, it is desirable to have seats within a vehicle that
 include a seat back that is pivotally supported on a seat bottom such that
 the seat back can be folded forward and downward relative to the seat
 bottom. Such an arrangement is necessary, for example, in vehicles so that
 a passenger can have access into the area behind the seat. In some
 vehicles, the seat back can be pivoted downwardly and forwardly into a
 horizontal position and the seat bottom along with the seat back can be
 pivoted forwardly into a vertical position to increase available cargo
 space in a vehicle.
 Seat adjuster assemblies that are used to mount the seat to the vehicle are
 often complex, especially when the adjusters include components to allow
 the seat back to be folded onto the seat bottom and then allow the seat
 bottom and back to be flipped to a stowed position. These complex adjuster
 assemblies require a great number of components, which increases the
 assembly time and the overall cost of the seat assembly. Also, these
 adjuster assemblies are bulky, requiring a significant amount of packaging
 space and are difficult for an occupant to access and operate.
 Accordingly, it is desirable to provide a simplified and inexpensive seat
 adjuster assembly that includes allows horizontal adjustment of the seat
 position but which also includes the capability of moving the seat to a
 stowed position in the vehicle. It is also desirable for the adjuster
 assembly to be durable and easy to operate.
 SUMMARY OF THE INVENTION
 In general terms, this invention is a vehicle seat assembly with a seat
 back pivotally supported with respect to a seat bottom, and which is
 attached to the vehicle by a mounting assembly with a seat adjuster. The
 seat can be folded down and flipped upwardly to increase the available
 cargo space within a vehicle. The seat adjuster includes a mount movable
 between a horizontal position and a vertical position. A seat back member
 is pivotally supported with respect to the mount and movable between an
 upright position and a folded position. A first lever is rotatably
 supported with respect to the mount and controls the movement of the seat
 back member when selectively actuated by a control assembly. A latch
 mechanism secures a portion of the mount to a vehicle structure and is
 movable between a latched position and an unlatched position. A second
 lever is rotatably supported with respect to the mount and controls the
 movement of the latch mechanism when selectively actuated by the control
 assembly such that the mount can be moved from the horizontal position to
 the vertical position when the latch is in the unlatched position.
 In a preferred embodiment of this invention, the vehicle seat assembly
 includes a first track, a second track supported for movement relative to
 the first track, a seat bottom supported on the second track for movement
 with the second track, and a seat back pivotally supported for pivotal
 movement relative to the seat bottom. The seat back is movable between an
 upright position and a folded position and the seat bottom is movable
 between a horizontal position and a vertical position or flipped position
 when the seat back has been moved to the folded position. The assembly
 includes a locking device that moves between a locked position where the
 second track is maintained in a selected position relative to the first
 track and an unlocked position where the second track is movable relative
 to the first track. The first lever is rotatably supported on the second
 track to control folding of the seat back. Once the seat back is folded
 down, the locking device is unlocked and the second track is moved to a
 rearwardmost position. The latch mechanism secures a rear portion of the
 first track to the vehicle structure and the second lever is rotatably
 supported on the second track to control the movement of the latch
 mechanism. After the seat back is folded onto the seat bottom and the
 second track has moved to a rearward position, the seat bottom, seat back,
 and tracks are flipped upwardly and forwardly when the latch mechanism is
 unlatched, thus moving the seat to a stowed position.
 The subject invention offers several advantages over prior art systems
 because it provides a simplified seat adjuster for a fold and flip seat
 that significantly reduces the number of required components and decreases
 overall assembly cost. The subject invention is also advantageous because
 it is durable, easy to assemble, and is easy to operate.
 These and other features and advantages of the present invention will be
 best understood from the following specification and drawings, the
 following of which is a brief description.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
 FIG. 1A illustrates a vehicle seat assembly 20. The seat assembly 20
 includes a seat bottom 22 that is mounted within the vehicle on a mounting
 assembly 24. A seat back 26 is pivotally supported for pivotal movement
 relative to the seat bottom 22. The mounting assembly 24 includes track
 assemblies on an inboard side and an outboard side of the seat assembly
 20, only the outboard side is shown. The mounting assembly includes a
 first track 28 and a second track 30. The second track 30 is slidably
 mounted on the first track 28 such that the seat 20 can be adjusted
 forwardly and rearwardly within the vehicle. A locking mechanism, shown
 schematically at 32, is used to fix the second track 30 relative to the
 first track 28 once the seat is in the desired position.
 A first release 34 is actuated to allow the seat back 26 to be folded
 downwardly toward the seat bottom 22 as shown in FIG. 1B. The seat 20 can
 be in any horizontal adjusted position when the first release 34 is
 actuated. Once the first release 34 is actuated or when the seat back 26
 reaches a full folded position, shown in FIG. 1C, the locking mechanism 32
 is unlocked and the seat 20 is moved to the rearwardmost position on the
 tracks 38, 30, shown in FIG. 1D. If the seat 20 is adjusted forwardly in
 the vehicle, the seat back 26 may not be able to be folded onto the seat
 bottom 22 because it might hit a front seat in the vehicle. Thus, if the
 seat 20 is adjusted forwardly the locking mechanism 32 will unlock when
 the first release 34 is actuated so that the seat 20 can be slid back and
 the seat back 26 can be fully folded onto the seat bottom 22. If the seat
 20 is adjusted rearwardly to allow full folding of the seat back 26, the
 locking mechanism 32 is unlocked to ensure that the seat 20 is in the
 rearwardmost position so that the mount can be unlatched.
 Once the locking mechanism 32 is unlocked and the seat 20 is slid
 rearwardly, as shown in FIG. 1D, the locking mechanism re-engages to
 securely lock the seat in the full rear position. A second release 36 is
 operably connected to a latch 38 that mounts the seat 20 to a vehicle
 floor 40. The second release 36 is actuated to unlatch the mounting
 assembly 24. After the seat 20 is unlatched, the seat 20 is pivoted from a
 horizontal position to a vertical position or stowed position, as shown in
 FIG. 1E. With the seat 20 in the stowed position, the cargo space in the
 vehicle is increased. Also, if the seat 20 is in the second row of seats
 in a vehicle having three rows of seats, when the seat 20 is in the stowed
 position it facilitates access to the third row of seats. To latch the
 seat 20 back to the vehicle floor, the seat 20 is flipped backward to
 automatically re-engage the latch.
 One embodiment of the subject vehicle seat adjuster is shown in FIG. 2. As
 discussed above, the mounting assembly 24 is comprised of a first track 28
 mounted to a vehicle floor 40 and a second track 30 slidably mounted on
 the first track 28 such that the seat 20 can be horizontally adjusted
 within the vehicle. A seat back member 42 pivotally supported with respect
 to the tracks 28, 30 is and movable between an upright position and a
 folded position. The seat back member 42 can be any component typically
 included in the seat back 26, such as a seat frame member, for example.
 A first lever 44 is rotatably supported with respect to the tracks 28, 30
 and is used to control the movement of the seat back member 42 between the
 upright and folded positions when selectively actuated by the first
 release 34. The first release 34 can be any type of release in the art,
 including having an actuator and cable assembly, for example. As shown in
 FIG. 2, a button or actuator lever 46 is mounted near a top portion 48 of
 the seat back member 42. A cable 50 extends along the length of the seat
 back member 42 and operably connects the actuator lever 46 to the first
 lever 44. The first lever 44 preferably includes a mounting portion or tab
 52 to which the cable 50 is attached. The tab 52 can be an extension that
 is integrally formed on the lever 44 as a single piece, or can be a
 separate piece that is attached to the lever 44. When the actuator lever
 46 is manually actuated, as shown in FIG. 3, the cable 50 pulls upwardly
 on the tab 52 causing the first lever 44 to rotate. Once the first lever
 44 is rotated out of the way, the seat back member 42 can be rotated from
 a vertical position to a horizontal position, as shown in FIG. 4.
 The latch mechanism 38 is used to secure a portion of the mounting assembly
 24 to the vehicle floor 40. The latch mechanism 38 is movable between a
 latched position and an unlatched position and includes a claw 54 that is
 pivotally mounted to the second track 30. A striker 56 is fixedly mounted
 to the vehicle floor 40. When the latch mechanism 38 is in the latched
 position, the claw 54 engages the striker 56 such that the mounting
 assembly 24 remains fixed relative to the vehicle floor 40.
 A second lever 58 is rotatably supported with respect to the tracks 28, 30
 and is used to control the movement of the latch mechanism 38 between the
 latched and unlatched positions when selectively actuated by the second
 release 36. The second release 36 is preferably an extension 60 of the
 second lever 58 that extends rearwardly from the seat 20 such that the
 extension 60 can be manually actuated to rotate the second lever 58. When
 the second release 36 is actuated, the second lever 58 is rotated and the
 latch mechanism 38 is moved to the unlatched position. As the second lever
 58 is rotated, it engages the claw 54 and rotates away from the striker 56
 to release the mounting assembly 24 such that the mounting assembly 24 can
 be moved from the horizontal position to the vertical position.
 Preferably, the seat 20 is pivoted to the vertical or stowed position on a
 pin shaft 62 that is mounted to the vehicle floor 40. A bracket 64 is
 mounted to a front portion of the first track 28 and includes a slot 66
 for receiving the pin shaft 62. The slot 66 extends horizontally along the
 first track 38 to allow slight horizontal movement of the pin shaft 62 in
 the slot 66. The seat tracks 28, 30 are pivoted about an axis of rotation
 defined by the pin shaft 62 when the latch mechanism is moved to the
 unlatched position and the seat 20 is flipped to the vertical position.
 A more detailed view of the seat adjuster assembly is shown in FIG. 5. As
 discussed above, the mounting assembly 24 is comprised of the first track
 28 mounted to the vehicle floor 40 to define a longitudinal axis 68. The
 second track 30 is supported for movement relative to the first track 28
 along the longitudinal axis 68. A pivot bracket 70 is supported on the
 second track 30 for movement therewith. The seat back member 42 is mounted
 to the pivot bracket 70 on a first pivot shaft 72 that defines an axis of
 rotation 76, shown in FIG. 6A. The seat back member 42 is pivoted on the
 first pivot shaft 72 as the seat back 26 is folded onto the seat bottom
 22.
 The first 44 and second 58 levers are mounted on a second pivot shaft 74
 which defines an axis of rotation 78, shown in FIG. 6B. Preferably the
 axes of rotation 76, 78 are parallel to each other. The first 44 and
 second 58 levers are supported on the second pivot shaft 74 for
 independent rotation about the axis of rotation 78. Thus, the first
 release 34 rotates the first lever 44 on the second pivot shaft 74 and the
 second release 60 rotates the second lever 58 on the second pivot shaft 74
 independently from the first lever 44. A torsion spring 80 is also mounted
 to the second pivot shaft 74 for assisting with the return of the seat
 back member 42 to the upright position.
 As shown in FIG. 6C, the seat back member 42 includes a recess 82 that
 receives the first lever 44 when the seat back 26 is in the upright
 position. The first lever 44 includes a cam 84 that engages the recess 82
 to prevent the seat back member 42 from moving to the folded position
 until the first release 34 is actuated. When the first release 34 is
 actuated, the first lever 44 is rotated about the axis 78 and the cam 84
 is moved out of the recess 82, as shown in FIG. 7. Once the cam 84 is
 moved out of the recess 82 the seat back member 42 can be pivoted to the
 folded position as shown in FIGS. 8A and 8B
 FIGS. 8A and 8B show the seat 20 in the folded and latched position. To
 move the seat 20 to the stowed position the mounting assembly 24 must be
 unlatched and the seat 20 must be pivoted from the horizontal position to
 the vertical position. The second lever 58 includes an elongated body 86
 with a transversely extending arm 88 at one end that engages the latch
 mechanism 38 to move the latch mechanism 38 from the latched position to
 the unlatched position when actuated by the second release 36. As
 discussed above, the second release 36 is an extension 60 formed on an
 opposite end of the second lever 58. The extension 60 extends rearwardly
 from the pivot bracket 70 such that the extension 60 can be manually
 actuated.
 The latch mechanism 38 is mounted to the first track 28 and includes the
 rotatable claw 54. The claw 54 has a hooked portion 90 that engages the
 striker 56 mounted to the vehicle floor 40 when the latch mechanism is in
 the latched position. The arm 88 of the second lever 58 engages a surface
 92 on the rotatable claw 54 causing the hooked portion 90 to rotate and
 disengage from the striker 56 the extension 60 is actuated, as show in
 FIGS. 9A and 9B.
 FIG. 10 shows the seat back member 42 in the folded position with the latch
 mechanism 38 in the latched position. The seat 20 is adjusted forwardly on
 the tracks 28, 30. Note that the arm 88 of the second lever 58 when
 rotated cannot engage the claw 54. This is because the seat 20 is too far
 forward. When the seat back member 42 is folded down, the locking
 mechanism 32 unlocks to automatically move the seat 20 to the rearwardmost
 position in the vehicle, shown in FIG. 11. In this position, when the arm
 88 is rotated, it can engage the claw 54 to unlatch the seat tracks 28, 30
 from the striker 56.
 The locking mechanism 32 can be any seat track locking mechanism known in
 the art. As shown in FIG. 5, the locking mechanism 32 can be a locking
 pawl 94 that is rotatably mounted for movement with the second track 30.
 The locking pawl 94 includes a plurality of fingers 96 that are received
 in slots 98 located in the track members 28, 30. When the first release 34
 is actuated or when the seat back 26 is in the fully folded position, the
 locking mechanism 32 is automatically disengaged to allow the seat 20 to
 be slid to the rearward most position. The locking mechanism 32 includes a
 resilient member 108 having a spring portion mounted to the second track
 30 for biasing the second track 30 to the rearwardmost position with
 respect to the first track 28. This spring assist allows the seat 20 to be
 quickly moved to the rearward position. Once the seat 20 is in this
 position the locking mechanism automatically re-engages. The locking pawl
 94 can be disengaged from the tracks 28, 30 by a cable control member (not
 shown) or by other means known in the art.
 As shown in FIGS. 5, 6A, 6B, 8A, and 9A, latch mechanism 38 further
 includes a locating bracket 100 fixedly mounted to the first track 28 with
 a centrally located slot 102. The striker 56 mounted to the vehicle floor
 40 is located and received within this slot 102 when the mounting assembly
 24 is in the latched position. The bracket 100 includes a first leg 104
 mounted on one side of the claw 54 and a second leg 106 mounted on an
 opposite side of the claw 54. The bracket 100 helps to locate the striker
 56 with respect to the claw 54 when the seat is returned from the vertical
 or stowed position to the horizontal or use position.
 As shown in FIGS. 6A-B, a block 112 is mounted between the tracks 28, 30.
 The block is fixed relative to the first track 28 and includes a slot 114
 on a top surface through which the arm 88 of the second lever 58 extends
 to engage the claw 54. Also shown in FIGS. 6A-B, is a secondary bracket
 member 116. The secondary bracket member 116 is mounted to the pivot
 bracket 70 between the first 44 and second 58 levers by a plurality of
 fasteners 118 as is known in the art.
 An alternate embodiment of the latch and lever mechanism is shown in FIGS.
 12-15. In this embodiment, the first 34 and second 36 releases are
 combined into a single control assembly. FIG. 12 shows the seat back
 member 42 in the upright position with the latch mechanism 38 in the
 latched position. The first 44 and second 58 levers are mounted on the
 common pivot shaft 74 as discussed with regard to the previous embodiment.
 In this configuration, however, the second lever 58 includes a hook tab
 110 for engaging the first lever 44 when the extension 60 is actuated to
 allow the seat back member 42 to move from the upright position to the
 folded position.
 One advantage with this configuration is that a single release is used to
 perform both the folding and the unlatching functions. As the extension 60
 is rotated upwardly, shown in FIG. 13, the hook tab 110 engages the first
 lever 44 causing the cam 84 of the first lever 44 to rotate out of the
 recess 82 of the seat back member 42. Once the first lever 44 is in this
 the seat back member 42 can be folded downwardly toward the seat bottom
 22, shown in FIG. 14. Note that the arm 88 of the second lever 58 is not
 positioned to engage the claw 54 and the latch mechanism remains in the
 latched position. When the seat 20 is moved to the rearwardmost position,
 shown in FIG. 15, the arm 88 can engage the claw 54 to move the latch
 mechanism 38 to the unlatched position when the extension 60 is rotated.
 Once the seat 20 is unlatched, it can be pivoted upwardly to the stowed
 position.
 The operation of folding the seat back 26 onto the seat bottom 22 and
 subsequently flipping the seat back 26 and bottom 22 to a stowed position
 in a vehicle is described below. The first lever 44 is rotated and the
 seat back 26 is folded down on the seat bottom 22. The locking device 32
 is unlocked, the second track 30 is moved to a rearwardmost position
 relative to the first track 30, and the locking device is re-engaged. The
 second lever 58 is then rotated to unlatch the latch mechanism 38.
 Finally, the seat bottom 22, seat back 26, and tracks 28, 30 are flipped
 upwardly to a stowed position.
 In one embodiment a first release 34 is actuated to rotate the first lever
 44 to a pre-selected position where the seat back 26 can be moved from the
 upright position to the folded position and a second release 36 is used to
 rotate the second lever 58 to move the latch mechanism 38 to the unlatched
 position such that the seat bottom 22 can be flipped upwardly. In another
 embodiment a single release 60 is actuated to rotate the first 44 and
 second 58 levers to fold and flip the seat 20.
 Preferred embodiments of this invention have been disclosed, however, a
 worker of ordinary skill in the art would recognize that certain
 modifications would come within the scope of this invention. For that
 reason, the following claims should be studied to determine the true scope
 and content of this invention.