Seatback lift mechanism for a supine motor vehicle seating assembly

A motor vehicle comprises an upper back support comprising a substantially U-shaped tubular member pivotally attached at a first end to one of a pair of opposed lateral seatback frame members and pivotally attached at a second end to the other of the pair of opposed lateral seatback frame members, a substantially rigid planar base attached to a central portion of the tubular member, a latch operably coupling the first end of the tubular member to the one of a pair of opposed lateral seatback members to restrain the tubular member in one of a plurality of positions between a stowed position and a fully raised position, and a cushion disposed above the upper back support to form a movable exposed surface.

FIELD OF THE INVENTION

The present invention generally relates to an apparatus and method for providing a motor vehicle seating assembly adapted to assume a first configuration to provide conventional support and restraint in the operation of motor vehicle, and adapted to assume a second configuration to provide a relatively level supine platform upon which an occupant might lie when the motor vehicle is not in operation and, more particularly, to a manually actuated adjustable seatback upper back support.

BACKGROUND OF THE INVENTION

Motor vehicle seating assemblies provided in modern motor vehicles are primarily designed to provide a support platform designed to accommodate a motor vehicle occupant in a sitting or reclined position, providing support for the motor vehicle occupant's back by which the motor vehicle occupant can safely operate the motor vehicle or travel within the motor vehicle in a comfortable and pleasant manner. Another function of motor vehicle seating assemblies is to assist in restraining the occupant in the event of an impact or rollover event. For example, in the case of a frontal impact event, the motor vehicle seating assembly is particularly adapted to restrain the occupant within a prescribed range of positions so that the motor vehicle's active and passive restraint systems can operate appropriately.

In the case of the lower seating structure of the motor vehicle seating assembly, the lower seating structure is typically downwardly inclined in a rearward direction toward the bite line of the motor vehicle seating assembly to provide an ergonomic seating platform. This configuration also serves to assist in positioning the H-point of the motor vehicle occupant of the motor vehicle seating assembly, whereby in the event of a frontal impact event, the forward momentum of the motor vehicle occupant generates a force against the lower seating assembly, which tends to retain the motor vehicle occupant in a position, where the active restraint system comprising the seatbelt assembly and the passive restraint system comprising one or more airbags can be most effectively employed.

However, modern motor vehicle seating assemblies typically do not address the needs of motor vehicle occupants when the vehicle is parked and the motor vehicle occupant wants to rest or sleep. Due to the mechanisms widely in use to provide a seatback recline feature, the seatback may cause significant discomfort when it moves from a driving/use design position to a resting/sleeping position. In particular, existing reclining features tend to create a substantial vertical gap between the lower seating structure and the seatback with the seatback in the fully reclined position. Likewise, the seatback often fails to provide sufficient upper back support when in the fully reclined position. Features are needed to make the motor vehicle occupant more comfortable and relaxed. Mechanisms that provide a relatively level supine platform and adequate upper back support are desired.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a seatback comprises a pair of frame members and an upper back support further comprising a tubular member pivotally attached to the pair of frame members, a support surface attached to the tubular member, and a latch operably coupling a first end of the tubular member to the one of the frame members to restrain the tubular member in one of a plurality of positions between a stowed position and a fully raised position.

Embodiments of the first aspect of the invention can include any one or a combination of the following features:a support surface comprising a substantially rigid planar base;a stowed position about 0° relative a plane of the seatback and a raised position about 15° relative the plane of the seatback;a plurality of positions of the upper back support in intervals of 1.5° between the stowed position and the fully raised position;a latch comprising a ratchet gear and ratchet pawl operably coupled with the ratchet gear, wherein displacement of the upper back support beyond the fully raised position actuates the ratchet pawl to an over travel condition to return the ratchet latch and the upper back support to the stowed position;an upper back support manually controlled by pulling the upper back support forward relative the seatback;a pull strap by which the upper back support is pulled forward relative the seatback;an upper back support pulled forward in increments of 1.5° between the stowed position and the fully raised position;a seatback frame having an upper transverse cross member, a lower transverse cross member, and a pair of opposed lateral seatback frame members extending between the upper and lower transverse members, each of the pair of opposed lateral seatback frame members having a seatback pivot mount at a lower portion thereof that is operably coupled with the lower seat pivot mount;a lower back support disposed below the upper back support operably coupled with the upper back support and raised relative a plane of the seatback when the upper back support is raised from the stowed position;a tubular member forming a substantially U-shaped and upwardly extending configuration within a plane of the seatback when in the stowed position and a substantially rigid planar base attached to the central portion of the tubular member;a head restraint having an exposed surface and a cushion disposed above the upper back support to form a movable exposed surface, and the exposed surface of the head restraint and the movable exposed surface of the upper back support forming a substantially continuous plane when the upper back support surface is in the raised position;a raised support proximate an upper edge of the substantially rigid planar base and disposed beneath a cushion;an upper back support disposed centrally between a first and second lateral edge of the seatback and below the heat restraint; anda foam pad and a resilient trim material disposed about the foam pad to maintain a flat surface and eliminate wrinkling between the stowed position and the fully raised position.

According to another aspect of the present invention, a seating assembly for a motor vehicle comprises a seatback pivotable between an upright position and a fully reclined position operably coupled with a lower seating structure, the seatback further comprising a frame having an upper transverse cross member, a lower transverse cross member, and a pair of opposed lateral seatback frame members extending between the upper and lower transverse members. Each of the pair of opposed lateral seatback frame members has a seatback pivot mount at a lower portion thereof that is operably coupled with the lower seat pivot mount. An upper back support comprising a tubular member is pivotally attached at a first end to one of the pair of opposed lateral seatback frame members and pivotally attached at a second end to the other of the pair of opposed lateral seatback frame members, a substantially rigid planar base is attached to a central portion of the tubular member, a latch operably couples the first end of the tubular member to the one of a pair of opposed lateral seatback members to restrain the tubular member in one of a plurality of positions between a stowed position and a fully raised position, and a cushion is disposed above the upper back support to form an exposed surface.

According to yet another aspect of the present invention, a seating assembly for a motor vehicle comprises an upper back support comprising a substantially U-shaped tubular member pivotally attached at a first end to one of a pair of opposed lateral seatback frame members and pivotally attached at a second end to the other of the pair of opposed lateral seatback frame members, a substantially rigid planar base attached to a central portion of the tubular member, a latch operably coupling the first end of the tubular member to the one of a pair of opposed lateral seatback members to restrain the tubular member in one of a plurality of positions between a stowed position and a fully raised position, and a cushion disposed above the upper back support to form a movable exposed surface.

According to another aspect of the present invention, a vehicle seating assembly includes a headrest and a seatback including a central portion and first and second lateral edges. The seatback is operable between an upright position and a reclined position. An upper back support includes a tubular member operably coupled between a bushing and a ratchet latch. The upper back support is adjustably securable in a plurality of positions by the ratchet latch. The vehicle seating assembly also includes a ratchet drive bracket. The tubular member is coupled to the ratchet drive bracket, the ratchet drive bracket is coupled to a drive gear of the ratchet latch, and movement of the tubular member between a stowed position and a fully deployed position causes the ratchet drive bracket to move the ratchet drive gear relative to a stationary gear.

Embodiments of the fourth aspect of the invention can include any one or a combination of the following features:a ratchet mounting bracket, wherein the ratchet mounting bracket secures the ratchet latch to a first bracket proximate the first lateral edge;a ratchet drive pin, wherein the ratchet drive pin secures the ratchet latch to the frame member;the ratchet drive bracket is selectively rotatable about the ratchet drive pin to move the ratchet drive gear relative to the stationary gear;the ratchet mounting bracket retains the ratchet drive gear and the stationary gear to the frame member;the ratchet mounting bracket retains the ratchet drive gear and the stationary gear in an engaged position;the ratchet drive gear comprises a first toothed portion, the stationary gear comprises a second toothed portion, and the first toothed portion and the second toothed portion are enmeshed and selectively positionable in a plurality of predetermined positions between the stowed position and the fully deployed position;the stowed position is about 0° relative to a plane of the seatback and the fully deployed position is about 15° relative to the plane of the seatback;the plurality of predetermined positions comprise intervals of 1.5° between the stowed position and the fully deployed position;an extension spring comprising a first end and a second end, wherein the first end is fixed to the tubular member and the second end is fixed to the ratchet mounting bracket and wherein the extension spring returns the upper back support from beyond a fully deployed position to a stowed position; andan extension spring comprising a first end and a second end, wherein the first end is fixed to the tubular member and the second end is fixed to the frame member and wherein the extension spring returns the upper back support from beyond a fully deployed position to a stowed position.

According to yet another aspect of the present invention, a seatback includes first and second frame members. The seatback also includes an upper back support. The upper back support includes a tubular member and a supporting member. The upper back support is located between the first and second frame members and is pivotably coupled to the first and second frame members. The seatback includes a drive bracket. The tubular member is coupled to the drive bracket, and the drive bracket is pivotably coupled to a ratchet pin that is coupled to the first frame member. The seatback also includes a ratchet mounting bracket. The ratchet mounting bracket secures a ratchet latch to the first frame member. The ratchet mounting bracket is coupled to the first frame member with the ratchet pin and a second attachment. A deployment force is exerted on the tubular member and causes the drive bracket and a drive gear to rotate about the drive pin relative to a stationary gear. The drive gear and the stationary gear are selectively engageable to place the tubular member in one of a plurality of predetermined positions.

Embodiments of the fifth aspect of the invention can include any one or a combination of the following features:the plurality of predetermined positions comprise a stowed position, a raised position, and/or an overtravel position;the plurality of predetermined positions further comprise intervals of 1.5° between the stowed position and the raised position;the supporting member comprises a first edge proximate a first lateral member of the seatback, a second edge proximate a second lateral member of the seatback, and a top edge proximate an upper transverse cross member of the seatback; andthe supporting member comprises a thermoplastic material forming a paddle member extending from an upper edge of the tubular member to the first edge, the second edge, and the top edge.

According to yet another aspect of the present invention, a mounting assembly for attaching a pivotable upper back support to a vehicle seatback frame includes a first bracket, a second bracket, and a ratchet latch. The ratchet latch is coupled to the first bracket with a ratchet mounting bracket. The mounting assembly for attaching a pivotable back support to a vehicle seatback frame also includes a bushing coupled to the second bracket. The upper back support also includes a support member pivotably coupled to the ratchet latch and the bushing.

Embodiments of the sixth aspect of the invention can include any one or a combination of the following features:a ratchet drive pin, wherein the ratchet drive pin retains the ratchet mounting bracket to the first bracket;a fully raised position includes alignment of a top surface of the upper back support with a top surface of a headrest, wherein the headrest is operably coupled to the vehicle seatback frame;the support member comprises a u-shaped tubular member with an overmolded thermoplastic paddle member; andthe ratchet latch is selectively positionable in a plurality of predetermined intermittent positions to arrange the upper back support between a stowed position and the fully raised position and wherein a spring force retracts the upper back support from beyond the fully raised position to the stowed position when the upper back support is beyond the fully raised position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS. 1-4, reference numeral10generally designates a vehicle seating assembly for use in a vehicle cabin8of a motor vehicle6. The motor vehicle seating assembly10includes a lower seating structure12pivotably coupled to a raised seatback14. As shown inFIGS. 1-2, the motor vehicle seating assembly10is generally configured for use in a variety of motor vehicles6in a front driver seat, a front passenger seat, or a rear seat of the motor vehicle6and generally includes the aforementioned lower seating structure12and raised seatback14. A head restraint26is also mounted to the top of the raised seatback14. The motor vehicle seating assembly10may be configured to be mounted on a support surface, such as a floor pan28of the vehicle6. A seat track assembly30may be coupled to the lower seating structure12to facilitate fore and aft positioning of the motor vehicle seating assembly10, as is known. The motor vehicle seating assembly10is generally designed for the comfort of a motor vehicle occupant, as well as to accommodate and protect the motor vehicle occupant during a collision event.

As best shown inFIG. 7, the lower seating structure12includes a forward seat pan34and a pair of opposed lateral lower seat frame members36,38having forward and rearward ends40,42attached to opposed lateral edges44,46of the forward seat pan34at the forward ends40of the opposed lateral lower seat frame members36,38. A pivot bar48extends laterally between and is fixedly attached to the rearward ends42of the opposed lateral lower seat frame members36,38. Preferably, the forward seat pan34and frame members36,38are fabricated from relatively low-weight and high-strength metal components, such as high-strength steel or aluminum. A lower seat pivot mount50is mounted at the rearward end42of the opposed lateral lower seat frame members36,38.

A cushion suspension system52is attached to the forward seat pan34and adjustably supported between the pair of opposed lateral lower seat frame members36,38. The cushion suspension system52includes a pair of lateral opposed suspension frame members54,56and a suspension cross member58extending between the pair of lateral opposed suspension frame members54,56. The pair of lateral opposed suspension frame members54,56and the suspension cross member58of the cushion suspension system52form an upper surface60in contact with and supporting a cushion foam and trim assembly62. At least one of the pair of opposed suspension frame members54,56form a lower surface100of the cushion suspension system52, as further discussed below. The cushion suspension system52further comprises a plurality of resilient members64, such as bent spring wires, extending between the pair of lateral opposed suspension frame members54,56that provide further support for the cushion foam and trim assembly62. As shown inFIGS. 5, 7, and 8, a forward portion66of the plurality of resilient members64are pivotally attached to the forward seat pan34of the lower seating structure12to allow the cushion suspension system52to be raised and lowered, as described below.

As noted above, the seatback14is pivotable between an upright position and a fully reclined position and is operably coupled with the lower seating structure12. The seatback14includes a frame68having an upper transverse cross member70, a lower transverse cross member72, and a pair of opposed lateral seatback frame members74,76vertically extending between the upper and lower transverse cross members70,72. Each of the pair of opposed lateral seatback frame members74,76has a seatback pivot mount78at a lower portion thereof that is operably coupled with the lower seat pivot mount50. Preferably, the seatback pivot mounts78on each of the pair of opposed lateral seatback frame members74,76comprise a circular recess80, and the lower seat pivot mount50mounted on each of the pair of opposed lateral lower seat frame members36,38comprises a circular projection82received within the circular recess80.

The motor vehicle seating assembly10further includes a hip lifter mechanism90, which comprises a pair of hip lifter pivot brackets92operably coupled with and pivotally disposed relative the pivot bar48. Each of the hip lifter pivot brackets92is preferably formed in a U-shape that fits over and is supported by the pivot bar48and is similarly fabricated from a lightweight yet strong metallic material. Each of the pair of hip lifter pivot brackets92is preferably disposed proximate one of the pair of opposed lateral lower seat frame members36,38. As shown inFIGS. 6-6D, each of the hip lifter pivot brackets92comprises a forward lever94and a rearward lever96. The forward lever94of each of the pair of hip lifter pivot brackets92is likewise preferably laterally disposed between the pair of opposed lateral lower seat frame members36,38and beneath one of the pair of lateral opposed suspension frame members54,56. So disposed, the forward lever94of the hip lifter pivot brackets92comprises a glide surface98that slidably engages and, upon further rotation, lifts a lower surface100of the cushion suspension system52. It is contemplated that the glide surface98may be coated with polytetrofluoride to provide lower friction and reduce wear.

A pair of frame attachment brackets102is operably coupled with preferably the lower portions84of the opposed lateral seatback frame members74,76, as shown inFIGS. 6-6D. Alternatively, the frame attachment brackets102may be attached to the lower transverse cross member72of the frame68of the seatback14, both preferably by welding. A link104is pivotally attached or pinned to each of the frame attachment brackets102at a first end106and pivotally attached or pinned to the rearward lever96of the hip lifter pivot brackets92at a second end108. The pivotable attachment of the first end106of the link104to the frame attachment bracket102is preferably accomplished by a pin110secured within an opening112,114in each of the first end106of the link104and the frame attachment bracket102, respectively, allowing relative pivotal motion. As shown inFIGS. 6-6D, the link104is provided with a slot116proximate the second end108that is operably coupled with the rearward lever96of the hip lifter pivot bracket92. The slot116of the link104has an upper end118and a lower end120. The rearward lever96of the hip lifter pivot bracket92also includes a pin122that is received within the slot116.

In operation, each of the forward levers94acts against the lower surface100of the cushion suspension system52. That is, when the seatback14is in the upright position, the lower end120of the slot116is proximate the pin122provided in the rearward lever96, as shown inFIG. 6A. Thus, when the lower end120of the slot116is proximate with the pin122, the seatback14position corresponds to the upright position of the seatback14. Similarly, as the seatback14is reclined, the upper end118of the slot116is brought into initial contact with the pin122provided in the rearward lever96, where the seatback14position corresponds to a predetermined reclined position between the upright position and the fully reclined position, as shown inFIG. 6B. Preferably, the predetermined reclined position of the seatback14is about 55.5° relative a vertical plane. Further rotation of seatback14toward the fully reclined position further displaces the rearward lever96of the hip lifter pivot bracket92downward, which, in turn, rotates the hip lifter pivot bracket92and raises the forward lever94, which then urges upwardly upon the lower surface100of the cushion suspension system52. This action raises the cushion suspension system52upwardly upon the seatback pivoting beyond the predetermined reclined position between the upright position and the fully reclined position.

As best shown inFIGS. 3 and 4, each of the lower seating structure12and the seatback14have an exposed surface124,126, respectively. Preferably, the exposed surface124comprises a locally flexible/stretch trim material relative to the cushion foam and trim assembly62that may be moved in order to keep the trim material and foam of the cushion foam and trim assembly62in tension to maintain a flat surface and eliminate wrinkling. In particular, a rear edge128of the cushion foam and trim assembly62of the lower seating structure12is raised by moving the seatback14to the fully reclined position, such that the cushion suspension system52raises the exposed surface124of the seat cushion foam and trim assembly62to substantially occupy the same horizontal plane as that of the exposed surface126of the seatback14when the seatback14is in a fully reclined position. This benefit might be most appreciated by comparing the relative exposed surfaces124,126inFIG. 6C, where the link104has been removed and the hip lifter mechanism90thus disabled, with the relative exposed surfaces124,126shown inFIG. 6D, where the link104is installed and the exposed surfaces124,126occupy substantially the same plane.

Preferably, the hip lifter mechanism90raises the cushion suspension system52and cushion foam and trim assembly62a distance H between 45 to 70 mm between the upright position and the fully reclined position of the seatback14to eliminate pressure on the lumbar and lifting the occupant's tailbone and hips, as shown inFIG. 9. The result is a substantially planar and continuous surface from the exposed surfaces124,126of the cushion foam and trim assembly62and seatback14, respectively. Preferably, the fully reclined position of the seatback14is reached at about 85° from vertical, extending from a front edge130of the lower seating structure12to an upper portion132of the seatback14.

In addition, the slotted linkage for the hip lifter mechanism90provides a passive system that automatically raises the height of the lower seating structure cushion foam and trim assembly62once the seatback14reaches a desired sleeper initiation angle, here preferably 55.5° from vertical, and achieves maximum lift of the cushion foam and trim assembly62once the seatback14reaches the maximum sleeper angle, here preferably 85° from vertical. Additional benefits of the hip lifter mechanism90disclosed herein is that the forward levers94are disposed between the cushion suspension system52and the lower seat frame side members36,38so as not to affect the seating assembly H-point or comfort when the seatback14of the seating assembly10is not in the fully reclined position or sleeper mode. Further, the maximum lift height of the rear edge128of the cushion foam and trim assembly62of the lower seating structure12can be readily modified and tuned to specific applications by relatively simple changes to the system geometry, such as the shape and length of the slot116.

Further, the hip lifter mechanism90represents a relatively simple mechanical system which can be manually actuated and does not require a motor, although a power actuated vehicle seating assembly can likewise beneficially employ the disclosed hip lifter mechanism90. In addition, existing seatback14recline latch controls134and associated mechanism can be readily employed to maintain the seatback14in the desired reclined position between the upright position and the fully reclined position, while simultaneously providing the lift function for the rear edge128of the lower seating structure cushion foam and trim assembly62beyond a predetermined reclined position. Finally, the disclosed hip lifter mechanism90is readily adaptable as a retrofit device to existing motor vehicle seating assemblies10.

Thus, to the extent that a motor vehicle occupant desires a supine position to rest when the motor vehicle6is not in operation, the aforementioned disclosure provides just such a platform upon which the motor vehicle occupant may rest. In accordance with the aforementioned disclosure, it is now possible to provide a more comfortable sleeping seat surface by raising the height of the rear edge128of the cushion foam and trim assembly62of the lower seating structure12to make the overall surface more level and the transition from the cushion foam and trim assembly62to the seatback14less noticeable.

Also, additional features can be added to the motor vehicle seating assembly10to provide an overall surface that is more level. In particular, the motor vehicle seating assembly10described above can further include an upper back support140that can be raised above a main body142of the seatback14within a range of a plurality of positions, between a stowed position and a fully raised position, where a moveable cushion144is attached to and disposed above the upper back support140to form an exposed surface162.

The upper back support140preferably includes a tubular member146pivotally attached at a first end148to one of the pair of opposed lateral seatback frame members74,76and pivotally attached at a second end150to the other of the pair of opposed lateral seatback frame members74,76. A substantially rigid planar base152is attached to a central portion154of the tubular member146, as shown inFIGS. 12 and 14. The central portion154of the tubular member146preferably forms a substantially U-shaped and upwardly extending configuration within a plane of the seatback14when in the stowed position, as shown inFIG. 12. The substantially rigid planar base152is preferably attached to the central portion154of the tubular member146by fasteners arranged in regular intervals, as shown inFIGS. 12 and 14. Preferably, the substantially rigid planar base152is shaped in a “paddle”-like configuration and further comprises a raised support156proximate an upper edge158of the substantially rigid planar base152and disposed beneath the movable cushion144. The substantially rigid planar base152of the upper back support140is preferably fabricated from a resilient plastic material, such as polypropylene, that provides sufficient support. The raised support156may be fabricated from foam padding or some other resilient material and is provided to ensure the desired height profile, as described herein.

The movable cushion144disposed above the upper back support140forms a movable exposed surface162, which may be similarly fabricated as a trim164and foam pad166assembly to provide a finished look, where the trim164is fabricated locally with a resilient, stretchable, or flexible fabric material that allows the upper back support140to readily move relative the seatback14. The use of a resilient trim material164disposed about the foam pad166further maintains a flat surface and eliminates wrinkling between the stowed position and the fully raised position.

Preferably, a ratchet latch170pivotally couples the first end148of the tubular member146to the inboard lateral frame member74. The ratchet latch170comprises a ratchet gear172and ratchet pawl174operably coupled with the ratchet gear172. The second end150of the tubular member146is pivotally attached to the other lateral seatback frame member74by a simple pivot176. The ratchet latch170operably couples the first end148of the tubular member146to the lateral seatback frame member76to restrain the tubular member146in one of a plurality of positions between the stowed position and the fully raised position. Preferably, displacement of the upper back support140beyond the fully raised position actuates the ratchet pawl174to an over-travel condition to return the ratchet latch170and the upper back support140to the stowed position. That is, when the upper back support140is rotated beyond the last latch position corresponding to the fully raised position, the upper back support140is returned to its design position by articulating full-forward and employing a spring to pull the upper back support140back to its design and fully stowed position.

Preferably, as shown inFIGS. 10-12 and 14, the upper back support140is disposed centrally between a first and second lateral edge180,182of the seatback14and below the head restraint26. Thus disposed, the upper back support140is designed to provide support between the shoulder blades of the motor vehicle occupant by use of a tubular member146to reduce muscle stress and increase neck blood flow. Similarly, as shown inFIGS. 3 and 4, the seatback14further includes the head restraint26, which itself forms an exposed surface178. As noted above, the movable cushion disposed above the upper back support140forms the movable exposed surface162. With the upper back support140in the fully raised position, the exposed surfaces162,178of the upper back support140and head restraint26, respectively, form a substantially planar surface, as seen inFIG. 4.

The upper back support140is preferably controlled manually by pulling the upper back support140forward relative the seatback14. In one embodiment, the upper back support140is moved from the stowed position to one of the plurality of positions by simply grasping the movable cushion144of the upper back support140and manually pulling the upper back support140forward to its desired raised position. Alternatively, the upper back support140may also include a pull strap184by which the upper back support140is pulled forward relative the seatback14.

In its stowed position, the upper back support140is preferably about 0° relative the plane of the seatback14. Conversely, in the fully raised position, the upper back support140is preferably about 15° relative the plane of the seatback14the distance D between 7 and 10 cm, as shown inFIGS. 11 and 14. The ratchet latch170, described above, provides a plurality of positions of the upper back support140, and preferably provides a discrete position in intervals of 1.5° between the stowed position and the fully raised position.

Thus, as noted above and as further described herein, the exposed surface178of the head restraint26and the movable exposed surface162of the upper back support140is capable of forming a substantially continuous plane when the upper back support surface is in the raised position. The upper back support140accordingly provides many of the desirable features noted above relative the hip lifter mechanism90.

In addition, a lower back support186may be disposed below the upper back support140, and the lower back support186may be operatively coupled with the upper back support140. Thus, when the upper back support140is raised from its stowed position, the lower back support186may be also raised relative a plane of the seatback14to provide a smooth and level transition between an exposed surface188of the lower back support186and the exposed surface162of the upper back support140, as shown inFIG. 10.

Referring toFIG. 16, a mounting assembly200for attaching a pivotable upper back support202to a vehicle seatback frame204is shown. The mounting assembly200for attaching a pivotable upper back support202to a vehicle seatback frame204includes a first bracket206and a second bracket208. In various aspects, the first bracket206and the second bracket208may be coupled to opposed lateral seatback frame members220,222. A tubular member210is located between the first bracket206and the second bracket208. A paddle member212is attached to the tubular member210. In the depicted aspect, the tubular member210is U-shaped, and the paddle member212is a thermoplastic material. A ratchet latch214is coupled to the first bracket206with a ratchet mounting bracket216.

Referring toFIG. 18, the ratchet mounting bracket216retains the drive gear260and the stationary gear262in an engaged position between the ratchet mounting plate268and the ratchet mounting bracket216.

Referring again toFIG. 16, a bushing218is coupled to the second bracket208. In the depicted aspect, the tubular member210is pivotally coupled to the ratchet latch214and the bushing218. With reference toFIG. 16, in various aspects of the disclosure, when the mounting assembly200is attached to opposed lateral seatback frame members220,222, the ratchet latch214is selectively positionable in a plurality of predetermined intermittent positions to arrange the upper back support202between the stowed position and the fully raised position, as exemplarily shown with regard to upper back support140inFIGS. 6C and 6D. Referring toFIGS. 16-17, a force depicted by arrow228is exerted on extension spring232when the upper back support202is moved from a stowed to a fully raised position in the direction shown by arrow234ofFIG. 16. The force depicted by arrow230retracts the extension spring232of the upper back support202from beyond the fully raised position (overtravel position or beyond a fully deployed position) to the stowed position when the upper back support202is beyond the fully raised position (overtravel position or beyond a fully deployed position).

Referring again toFIG. 16, the arrow234depicts the direction of rotation of the tubular member210and the paddle member212from the stowed position to the fully raised position.

With reference toFIG. 20, the fully raised position typically provides alignment of the exposed top surface236of the upper back support202with a top surface238of a head restraint240, as exemplarily shown inFIGS. 3A, 4, 6C, and 6Dwith regard to upper back support140upper portion132and head restraint26exposed surface178. In its stowed position, the upper back support202is typically about 0° relative to the plane of the seatback284. In the fully raised position, the upper back support202is typically about 15° relative to the plane of the seatback284.

Referring toFIGS. 16-18, the ratchet latch214provides a plurality of positions of the upper back support202, and typically provides a discrete position in intervals of 1.5° between the stowed position and the fully raised position.

Referring toFIG. 18, the drive gear260and the stationary gear262are selectively engageable to place the tubular member210in one of a plurality of predetermined positions.

Referring toFIG. 17, the ratchet drive pin242and the fastener252secure the ratchet mounting bracket216to the first bracket206. The ratchet mounting bracket216holds the ratchet latch214to the first bracket206. An extension spring232is coupled to the tubular member210and an aperture250in the ratchet mounting bracket216.

FIG. 18shows the ratchet latch214ofFIG. 17with the extension spring232, the ratchet mounting bracket216, and the fastener252removed from the mounting assembly200. The ratchet latch214includes the drive gear260and the stationary gear262. A ratchet backing plate268is retained by a ratchet drive pin242and held to the first bracket206. The ratchet backing plate268includes the stationary gear262. When tubular member210is moved from the stowed position to the deployed position in the direction depicted by arrow234ofFIG. 16, the drive bracket266rotates about the ratchet drive pin242to move the drive gear260in relation to the stationary gear262. A toothed portion270of drive gear260and a toothed portion272of the stationary gear262form a toothed interface274. The toothed interface274may be formed when a first toothed portion (toothed portion270of the drive gear260) and a second toothed portion (toothed portion272of stationary gear262) become enmeshed. The toothed interface274between the drive gear260and the stationary gear262allows for positioning the tubular member210in a plurality of positions between the stowed position and the fully deployed position. When the tubular member210is rotated in the direction depicted by the arrow234inFIG. 16, then a force depicted by arrow228is applied to the extension spring232, the extension spring232becomes elongated, and the drive bracket266rotates around the ratchet drive pin242in the direction depicted by arrow276. When the tubular member210is moved beyond the fully deployed position, the drive gear260and the stationary gear262separate at the toothed interface274due to the force depicted by arrow230exerted by the return of the extension spring232to a non-extended position. Referring again toFIGS. 17-18, the stationary gear262includes a lock pin280. The lock pin280protrudes through the hole282in the ratchet mounting bracket216. The lock pin280and the ratchet drive pin242retain the ratchet mounting bracket216to the ratchet backing plate268and the stationary gear262and keep the stationary gear262in a fixed position while the drive bracket266moves the drive gear260in relation to the stationary gear262.

Referring toFIGS. 19-20, the tubular member210is shown with an over-molded paddle member212. The paddle member212includes a first edge300proximate a first lateral member220of the seatback284, a second edge302proximate a second lateral member222of the seatback284, and a top edge304proximate an upper transverse cross member306of the seatback284. In the depicted aspect, a thermoplastic material forms the paddle member212and is molded around an upper portion310of the tubular member210to the first edge300, the second edge302, and the top edge304. In various aspects, the first upholstered portion290and the second upholstered portion292are attached to the tubular member210and the paddle member212. A tab may be manually pulled to move the upper support member202from the stowed position to the deployed position.

Referring toFIG. 21, an alternate aspect of a mounting assembly320for attaching a pivotable upper back support322to a vehicle seatback frame324is shown. The mounting assembly320for attaching a pivotable upper back support322to a vehicle seatback frame324includes a first bracket326and a second bracket328. In various aspects, the first bracket326and the second bracket328may be coupled to opposed lateral seatback frame members330,332. A tubular member340is located between the first bracket326and the second bracket328. A paddle member342is attached to the tubular member340. In the depicted aspect, the tubular member340is U-shaped and the paddle member342is a thermoplastic material. A ratchet latch344is coupled to the first bracket326with a ratchet mounting bracket346. A bushing348is coupled to the second bracket328. In the depicted aspect, the tubular member340is pivotally coupled to the ratchet latch344and the bushing348. With reference toFIG. 22, in various aspects of the disclosure, when the mounting assembly320is attached to opposed lateral seatback frame members330,332, the ratchet latch344is selectively positionable in a plurality of predetermined intermittent positions to arrange the upper back support322between the stowed position and the fully raised position, as exemplarily shown with regard to upper back support140inFIGS. 6C and 6D. Referring toFIG. 22, a force depicted by arrow358is applied to extension spring386. The tubular member340is rotated in the direction depicted by arrow364inFIG. 21. A force depicted by arrow360retracts the extension spring386of the upper back support322from beyond the fully raised position (overtravel position or beyond a fully deployed position) to the stowed position when the upper back support322is beyond the fully raised position (overtravel position or beyond a fully deployed position).

Referring again toFIG. 21, arrow364depicts the direction of rotation of the tubular member340and the paddle member342from the stowed position to the fully raised position. Referring toFIG. 20, the fully raised position includes alignment of an exemplary exposed top surface236of the upper back support322(exemplarily shown as upper back support302inFIG. 20) with a top surface238of a head restraint240, as exemplarily shown inFIGS. 3A, 4, 6C, and 6Dwith regard to upper back support140upper portion132and head restraint26exposed surface178. In its stowed position, the upper back support322is typically about 0° relative to the plane of the seatback284. In the fully raised position, the upper back support322is typically about 15° relative to the plane of the seatback284. The ratchet latch344provides a plurality of positions of the upper back support322, and typically provides a discrete position in intervals of 1.5° between the stowed position and the fully raised position.

Referring toFIG. 23, the drive gear380and the stationary gear382are selectively engageable to place the tubular member340in one of a plurality of predetermined positions. The ratchet drive pin370and the fastener374retain the ratchet mounting bracket346to the first bracket326.

Referring toFIGS. 21-23, the ratchet latch344includes the drive gear380and the stationary gear382. The ratchet mounting bracket346holds the ratchet latch344to the first bracket326. An extension spring386is coupled to the tubular member340and an aperture372in the first bracket326.

FIG. 23shows the ratchet latch344ofFIGS. 21-23with the ratchet backing plate376removed from the mounting assembly320. The ratchet backing plate376is shown removed from the ratchet drive pin370and the lock pin378. The ratchet latch344includes a drive gear380and a stationary gear382. The ratchet drive pin370and the lock pin378hold the ratchet backing plate376over the drive gear380and the stationary gear382. The ratchet drive pin370fits in aperture371of the ratchet backing plate376. When the tubular member340is moved from the stowed position to the deployed position in the direction depicted by arrow364ofFIG. 21, the drive bracket350rotates about the ratchet drive pin370to move the drive gear380in relation to the stationary gear382. When the tubular member340is rotated in the direction depicted by arrow364inFIG. 21, then a force depicted by arrow384is applied to the extension spring386, and the extension spring386becomes elongated. When the tubular member340is rotated in the direction depicted by arrow364inFIG. 21, then the drive bracket350rotates around the ratchet drive pin370in the direction depicted by arrow388. As the drive gear380is rotated, the stationary gear382typically stays in place. A toothed portion390of drive gear380and a toothed portion392of stationary gear382form a toothed interface394. The toothed interface394may be formed when a first toothed portion (toothed portion390of drive gear380) and a second toothed portion (toothed portion392of stationary gear382) become enmeshed. The toothed interface394between the drive gear380and the stationary gear382allows for positioning the tubular member340in a plurality of positions between the stowed position and the fully deployed position. When the tubular member340is moved beyond the fully deployed position, the drive gear380and the stationary gear382separate at the toothed interface394due to the force depicted by arrow396exerted by the return of the extension spring386to a non-extended position. The stationary gear382includes a lock pin378. The lock pin378protrudes through the hole398in the ratchet backing plate376. The ratchet drive pin370and the lock pin378retain the ratchet backing plate376over the drive gear380and the stationary gear382to keep the stationary gear382in a typically fixed position while the drive bracket350moves the drive gear380in relation to the stationary gear382. The ratchet drive pin370fits into the aperture371of the ratchet backing plate376.

Referring toFIG. 24, a side view of the first bracket326and the extension spring386is shown. The ratchet drive pin370and the fastener374attach the ratchet mounting bracket346to the first bracket326.

The upper back supports202,322may be fabricated separately from the seatback284. In various aspects, upper back supports202,322may be trimmed and may be inserted into a trimmed seatback284, thus providing a modular assembly solution.

It will be understood by one having ordinary skill in the art that construction of the present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “operably connected” generally means that one component functions with respect to another component, even if there are other components located between the first and second component, and the term “operable” defines a functional relationship between components.