Device and method for assembling a recliner mechanism

An adjustable pivot rotatably supports and adjusts a position of a pivoting member within a housing. The adjustable pivot includes a central cylinder defining a first axis and rotatably supporting the pivoting member. A second cylinder extends from the central cylinder and defines a second axis offset from and parallel to the first axis. The second cylinder is supported by the housing and operable for rotation about the second axis to an adjustment position. Rotation of the second cylinder to the adjustment position causes the first axis to orbit about the second axis to an adjusted position. In this manner, the pivoting member is adjustably positioned within the housing.

FIELD OF THE INVENTION

The present invention relates to relates generally to recliner mechanisms and, more particularly, to a device and method for assembling a recliner mechanism.

BACKGROUND OF THE INVENTION

Rotary recliner mechanisms generally include of a first rotary member having a plurality of teeth and a second rotary member including one or more pawls adapted to lockingly engage the teeth to couple the rotary members to one another. Typically, one rotary member is mounted to a quadrant for attachment to a seat back and the second rotary member is mounted to a base plate for attachment to a seat base. The rotary recliner mechanisms are operable to lock the rotary member connected to the seat back to restrict its rotation, or to release the rotary member connected to the seat back to allow it to rotate and to enable the seat back to recline.

The rotary recliner mechanism is selectively locked or released by manipulating the one or more pawls, which are mounted for rotation between an engaged position where the teeth of the pawl and the teeth of the rotary member connected to the seat base mesh, and a disengaged position where the pawl retracts and no longer meshes with the teeth of the rotary member connected to the seat base. Locking rotary recliner mechanisms also may include a device, such as a spring, for releasably urging the pawl from the disengaged to the engaged position so that the default position for the mechanism is a locked condition. Further, the rotary recliner typically includes an activating mechanism that moves the pawl from the engaged position to the disengaged position.

In reclining seats, the seat back functions as an extremely long lever arm against which various forces are applied. The locking rotary recliner mechanism in a vehicle seat is relatively small compared to the length of the reclining seat back, and vehicle vibration or movement of an occupant may impose various forces upon that lever during use. These forces impose a large moment about the rotary member connected to the seat back when applied along such a lengthy lever arm. Any imperfection in the components of the pivot mechanisms, such as play or backlash between the engaging teeth or tolerances between the mechanism components, may allow the rotary member connected to the seat back to move a minuscule amount even when the mechanism is locked. These small movements are magnified by the length of the lever arm and become noticeable at the upper end of the seat. This magnified play in locking pivot mechanisms has been termed “chucking” and refers to any imperfections or play in the mechanism components that allow movement of the rotary member and attached seat back while the mechanism is in a locked condition.

One technique employed to reduce chucking is to form the components of the pivot mechanism with exceedingly close tolerances. Manufacturing to such close tolerance is difficult and expensive because precision machining is required. Further, close tolerances may bind the components of the system and prevent smooth operation.

SUMMARY OF THE INVENTION

The present invention provides an adjustable pivot to rotatably support and adjust a position of a pivoting member within a housing. The adjustable pivot includes a central cylinder defining a first axis and rotatably supporting the pivoting member. A second cylinder extends from the central cylinder and defines a second axis offset from and parallel to the first axis. The second cylinder is supported by the housing and operable for rotation about the second axis to an adjustment position. Rotation of the second cylinder to the adjustment position causes the first axis to orbit about the second axis to an adjusted position. In this manner, the pivoting member is adjustably positioned within the housing.

In one feature, the adjustable pivot further includes a third cylinder extending from the central cylinder. The third cylinder defines a third axis aligned with the second axis. The third cylinder is supported by the housing.

In another feature, rotation of the third cylinder about the third axis induces orbiting of the first axis about the third axis to adjust a position of the pivotal member within the housing.

In still another feature, the adjustable pivot further includes a relief formed in a face of the second cylinder. The relief is engageable by a tool to induce rotation of the second cylinder.

In yet another feature, the second cylinder is staked in the adjusted position to the housing to prohibit rotation of the second cylinder about the second axis.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS. 1 through 7, an exemplary compact recliner assembly10includes an outer housing12having a support plate14fixed thereto, and an inner housing16supported within the outer housing12and covered by a cover plate18. The inner housing16supports a locking pawl20and a pair of locking cams22. The locking pawl20is slidable between a locked position, engaging an inner circumferential surface24of the outer housing12, and an unlocked position, disengaging the inner circumferential surface24. The locking cams22are movable between locked and unlocked positions (seeFIGS. 4 and 6, respectively) to correspondingly lock the locking pawl20in its locked position.

The outer housing12is fixed to the support plate14by fasteners (not shown) that are received through apertures26of the outer housing12and apertures28of the support plate14. A lower flat30of the outer housing12seats within a bracket32extending from the support plate14. The outer housing12includes an oversized aperture34that forms the inner circumferential surface24. A series of teeth36are formed in a section of the inner circumferential surface24. Teeth37of the locking pawl20selectively engage the teeth36.

The inner housing16seats within the aperture34of the outer housing12and includes an outer circumferential surface38. The outer circumferential surface38slidably engages the inner circumferential surface24of the outer housing. In this manner, the outer housing12is rotatably supported about the inner housing16. The inner housing16also includes a cylindrical extension40that defines an outer circumferential surface42. The cylindrical extension40is received into an aperture44of the support plate14that defines an inner circumferential surface46. The outer circumferential surface42and the inner circumferential surface46are slidably engaged to support the support plate14about the inner housing16. The inner housing16includes a pawl slot48and cam recesses50formed therein.

The inner housing16is anchored in a fixed position by anchors49. The anchors49are received through apertures51and are secured to a fixed structure (not shown) by bolts (not shown). In this manner, the inner housing16is fixed relative to the support structure and the outer housing12is rotatable about the fixed inner housing16.

A cam plate52is rotatably supported within the inner housing16and engages the locking pawl20and the locking cams22for moving each between the locked and unlocked positions. The cam plate52is supported about a pivot54that extends through a central aperture56of the inner housing16and a central aperture58of the cover plate18. The pivot54includes a central cylindrical section60having a step with keyed surfaces62. A tapered cylindrical section64extends through and is supported within the central aperture56of the inner housing16. The central cylindrical section60seats within a recess66of the central aperture56. A cylindrical section68extends through and is supported within the central aperture58of the cover plate18. A keyed section70extends from an end of the cylindrical section68.

The cam plate52includes a cam slot72and a central aperture74having keyed flats76formed therein. A post78of the locking pawl20is received into the cam slot72and is slidable therein. The pivot54is received through the central aperture74, whereby the keyed surfaces62engage the keyed flats76of the central aperture74. In this manner, the cam plate52is fixed for rotation with the pivot54. The cam plate52further includes engagement edges80that slidably engage the locking cams22.

The locking cams22include a central aperture82, an upper jamming edge84, a lower jamming edge86, and a raised surface88. The locking cams22are pivotally supported within the cam recesses50about adjustable pivots90. The pivots90each include a central cylindrical section92defining an axis A and extending cylindrical sections94defining an axis B. As best seen inFIG. 5, the central cylindrical section92is concentrically offset from the extending cylindrical sections94. In other words, axis A is offset from axis B. A groove95is formed at an end of the extending cylindrical sections94. The central cylindrical section92is received through the aperture82of the locking cam22and includes a bearing surface96about which the locking cam22is rotatably supported. The extending cylindrical sections94are received through apertures98,100of the inner housing16and cover plate18, respectively, to support the pivot90therebetween.

In the locked position the locking cams22act as columns biasing the locking pawl20into engagement with the inner circumferential surface24. The upper jamming edges84of the locking cams22engage the locking pawl20and the lower jamming edges86engage a surface102of the inner housing16. In this manner, the locking cams22prohibit inward radial sliding of the locking pawl20. In the unlocked position the locking cams22are dislocated from engagement with the locking pawls20and surface102to enable the inward radial sliding of the locking pawl20.

During assembly, tolerances between the locking cams22are minimized to ensure the locking cams22properly contact the locking pawl20and the surface102when in the locked position. The locking pawl20and locking cams22are set in the locked position. This position is deemed neutral and it is relative to this position that the locking cams22are moved to an adjusted position to minimize tolerances. To minimize tolerances, the relative positions of the locking cams22between the locking pawl20and the surface102are adjusted by rotating the pivots90within the apertures98,100. Rotation of the pivots90is induced inserting a flat-head tool (e.g., screwdriver) into the grooves95. Rotation of the pivots90within the apertures98,100induces the axis A to orbit axis B in directions X1or Y1. The central cylindrical sections92rotate within apertures82of the locking cams22. Movement of axis B about axis A induces planar movement of the locking cams22within the inner housing16to an adjusted position. The locking cams22move in directions X2and Y2to adjust the locking cams22between the locking pawl20and the surface102. Once the adjusted position of the locking cams22is achieved, the pivots90are staked to the inner housing16and the cover plate18. In this manner, the pivots94are fixed from rotating after assembly, thereby fixing the position of the locking cams22between the locking pawl20and the surface102.

The locking cams22are biased into the locked position by a compression spring104. The compression spring104seats within a spring recess106partially defined by the surface102. The compression spring104seats between flats108of the locking cams22to exert a biasing force on the locking cams22. The engagement edges80of the cam plate52slidably engage corresponding edges110of the raised surfaces88. As the cam plate52is induced to rotate, the engagement edges80bias the locking cams22to rotate about the pivots90to the unlocked position. As the locking cams22rotate, the flats108compress the compression spring104. Upon release of the cam plate52, the compression spring104biases the locking cams22into the locked position. As the locking cams22rotate back to the locked position the cam plate52is induced to rotate, urging the locking pawl20back into engagement with the teeth36of the inner circumferential surface24.

Referring now toFIG. 6, the compact recliner assembly10is integrated into a seat assembly120. The seat assembly120includes a seat122and a seat back124. The inner housing16is fixed to the seat122by the anchors49. The seat back124is fixed to the support plate14. Rotation of the outer housing12about the inner housing16facilitates corresponding pivoting of the seat back124relative to the seat122. A handle126is fixed to the keyed section70of the pivot54. The handle126is actuated by an operator to induce rotation of the pivot54, thereby facilitating operation of the compact recliner assembly10as described above.

It is appreciated that the compact recliner assembly10is merely exemplary in nature and is only one example of many types of recliner assemblies known in the art. It is anticipated that the adjustable pivots90can be implemented in any type of recliner assembly. Implementation of an adjustable pivot reduces chucking by compensating for tolerances between recliner assembly components.