Rigidifying system for single shell juvenile vehicle seat

A child restraint includes a juvenile seat including a seat shell and a rigidifying structure for the seat shell. The seat shell includes a seat bottom and a seat back extending upwardly from the seat bottom.

BACKGROUND

The present disclosure relates to child restraints, and in particular, to juvenile seats for use on passenger seats in vehicles. More particularly, the present disclosure relates to rigidifying structures included in juvenile seats.

SUMMARY

According to the present disclosure, a child restraint includes a juvenile seat and a child-restraint harness coupled to the juvenile seat. The juvenile seat includes a seat shell formed to include a seat bottom and a seat back extending upwardly from the seat bottom.

In illustrative embodiments, the juvenile seat includes a rigidifying structure comprising two separate stiffener beams coupled to the seat shell. Fasteners are used to couple each stiffener beam to the seat bottom and back of the seat shell so that the stiffener beams are fixed in a stationary uniformly spaced-apart relation to one another. In illustrative embodiments, each stiffener beam is J-shaped to resemble a hockey stick.

In illustrative embodiments, the seat shell is a monolithic piece having a front side facing toward a child seated on the seat bottom and an oppositely facing rear side. The seat shell includes rearwardly extending first and second ribs. Each rib is formed to include a beam-receiver channel having an opening on the front side of the seat shell and extending from the front edge of the seat bottom to the top edge of the seat back. Each of the stiffener beams is inserted into a companion beam-receiver channel formed in one of the ribs through the opening formed in the front side of the seat shell and held in place by a fastener to rigidify the seat shell.

DETAILED DESCRIPTION

An illustrative child restraint10comprises a juvenile seat12, a child-restraint harness14, and an energy-dissipation system16as suggested inFIGS. 1,5, and11. In illustrative embodiments, juvenile seat12includes a seat shell20formed to include first and second beam-receiver channels21,22, a headrest18, a headrest-height controller19, and first and second stiffener beams121,122as suggested inFIGS. 1,2, and5. Each of stiffener beams121,122is inserted into one of the beam-receiver channels21,22and coupled to seat shell20using fasteners24as suggested inFIG. 5to rigidify juvenile seat12as suggested inFIGS. 1-4and11.

Headrest18is mounted for up-and-down movement on seat shell20and configured to carry air-filled ride-down pads161,162,163, and164included in energy-dissipation system16as suggested inFIG. 1. In illustrative embodiments, headrest18includes a head cradle40and a slidable cradle-retainer plate60coupled to head cradle40to move therewith relative to a portion of seat shell20located between head cradle40and slidable cradle-retainer plate60as suggested inFIG. 5.

Headrest-height controller19is coupled to headrest18and seat shell20and is configured to control the height of headrest18relative to seat shell20. Headrest-height controller19includes an actuator handle58located near the top of headrest18as suggested inFIG. 2. Actuator handle58can be moved by a caregiver to release headrest18from a locked position on a seatback24of seat shell20so that headrest18can be raised or lowered on a seat back24. It is within the scope of this disclosure to use any suitable headrest-height controller.

Seat shell20includes a seat bottom23and a seat back24arranged to extend upwardly from seat bottom23and terminate at a top edge25as shown, for example, inFIG. 5. In illustrative embodiments, seat shell20also includes a first side-wing panel26coupled to one side of seat bottom73and seat back24and an opposing second side-wing panel27coupled to an opposite side of seat bottom23and seat back24as suggested inFIG. 5. Each of seat bottom23and seat back24is arranged to extend laterally between first and second side-wing panels26,27and carry first and second stiffener beams121,122as suggested inFIGS. 1 and 5.

In illustrative embodiments, seat shell20is a monolithic element made of a polypropylene material. A front side20F of seat shell20is shown for example, inFIGS. 1 and 5. A rear side20F of seat shell20is shown, for example, inFIGS. 2,6, and11. In illustrative embodiments, an outer fabric covering28included in juvenile seat12is mounted on seat shell20to cover seat shell20and first and second stiffener beams121,122as suggested inFIG. 1.

Seat shell20is formed to include rearwardly extending first and second ribs221,222as shown, for example, inFIGS. 1-6. In illustrative embodiments, lower portions221L,222L of ribs221,222are formed in seat bottom23and upper portions221U,222U of ribs221,222are formed in seat back24as shown, for example, inFIGS. 1-5. As suggested inFIG. 5, seat bottom23also includes a seat pad28located between lower portions of first and second ribs221,222and seat back24includes a backrest30located between upper portions of first and second ribs221,222.

First rib221is formed to include first beam-receiver channel21as suggested inFIGS. 1-5. In illustrative embodiments, each of first rib221, first stiffener beam121, and first beam-receiver channel21is substantially J-shaped. As suggested inFIG. 5, seat bottom and back23,24are formed to include an elongated first aperture321opening into the first beam-receiver channel21formed in first rib221of seat shell20. In illustrative embodiments, first beam-receiver channel21has an opening formed in front side20F of seat shell20as suggested inFIG. 5. As suggested inFIG. 5, during assembly of components included in juvenile seat12, first stiffener beam121is inserted into first beam-receiver channel21and held in a stationary position therein by means of fasteners24coupled to first stiffener beam121and seat shell20.

Second rib222is formed to include second beam-receiver channel22as suggested inFIGS. 1-5. In illustrative embodiments, each of second rib222, second stiffener beam122, and second beam-receiver channel22is substantially J-shaped. As suggested inFIG. 5, seat bottom and back23,24are formed to include an elongated second aperture322opening into the second beam-receiver channel22formed in second rib222of seat shell20. In illustrative embodiments, second beam-receiver channel22has an opening formed in front side20F of seat shell20as suggested inFIG. 5. As suggested inFIG. 5, second stiffener beam122is inserted into second beam-receiver channel22during manufacture of juvenile seat12and held in a stationary position therein by means of fasteners424coupled to second stiffener beam22and seat shell20.

A seat pad28included in seat bottom23is visible on front side20F of seat shell20as suggested inFIG. 5. Seat pad28lies between lower portions of first and second beam-receiver channels21,22and extends laterally from an inner edge231ibordering first aperture321associated with first beam-receiver channel21to an inner edge232ibordering second aperture322associated with second beam-receiver channel22as suggested inFIG. 5. Seat pad28is formed to include several crotch belt-receiving slots281,282as suggested inFIG. 5.

Backrest30included in seat back24is visible on front side20F of seat shell20as suggested inFIG. 5. Backrest29lies between upper portions of first and second beam-receiver channels21,22and extends laterally from inner edge231ibordering first aperture321associated with first beam-receiver channel21to inner edge232ibordering second aperture322associated with second beam-receiver channel22as suggested inFIG. 5.

Each of first and second stiffener beams121,122is substantially J-shaped to resemble a hockey stick as shown, for example, inFIG. 5. A lower portion121L,122L of each of first and second stiffener beams121,122is a forwardly and generally horizontally extending blade. An upper portion121U,122U of each of first and second stiffener beams121,122is an upwardly extending handle coupled to a rear end of a companion blade and arranged to cooperate with the companion blade to define an obtuse included angle100of about 100° therebetween as suggested inFIG. 5. Each stiffener beam121,122is made of a polypropylene material in an illustrative embodiment.

Each of first and second stiffener beams121,122includes a perimeter flange140and a rigidifying structure150. Perimeter flange140is formed to include an interior space401bounded by perimeter flange140as suggested inFIG. 5. Rigidifying structure150is located in interior space1401and coupled to perimeter flange140.

Each perimeter flange140includes a J-shaped topside wall143, a J-shaped underside wall141arranged to lie in spaced-apart relation to J-shaped topside wall143, and a front wall142arranged to interconnect forward ends of each of J-shaped topside and underside walls143,141as suggested inFIG. 5. In illustrative embodiments, each perimeter flange140also includes a peak wall144arranged to interconnect opposite rearward ends of each of J-shaped topside and underside walls143,141as suggested inFIG. 5. In illustrative embodiments, front wall142is substantially flat and cooperates with a flat front portion143F of J-shaped topside wall143to define an acute included angle of about 65° therebetween and with a flat front portion141F of J-shaped underside wall141to define an obtuse included angle of about 110° therebetween as suggested inFIG. 5.

Rigidifying structure150of each of first and second stiffener beams121,122includes upright first bottom and top plates151,153and a first stiffener-beam internal truss system152in an illustrative embodiment as shown, for example, inFIG. 5. Upright first bottom plate151is coupled to each of J-shaped topside and underside walls143,141of first stiffener beam121. Upright first top plate153is coupled to each of J-shaped topside and underside walls143,141of first stiffener beam121. First stiffener-beam internal truss system152is arranged to interconnect upright first bottom and top plates151,153as suggested inFIG. 5.

As suggested inFIG. 5, headrest18includes a head cradle40and a slidable cradle-retainer plate60. Cradle-retainer plate60is coupled to head cradle40to move therewith relative to seat back24and to retain head cradle40in tethered relation to seat back24while allowing up-and-down movement of head cradle40relative to seat back24.

Backrest30is formed to include a pair of upwardly extending and laterally spaced-apart belt travel channels31,32shown, for example, inFIGS. 1,5, and11. These belt-travel channels31,32are provided so that shoulder belts241,242in child-restraint harness14can pass between front and rear sides20F,20R of seat shell20. Headrest18is aligned with seat back14so that belt-receiving slots181,182formed in head cradle40and belt-receiving slots61,62formed in slidable cradle-retainer plate60of headrest18are always aligned with belt-travel channels31,32formed in backrest30regardless of the position of headrest18on seat back24.

A first shoulder belt241included in child-restraint harness14is arranged to extend through first belt-travel channel31as suggested inFIGS. 5 and 11. First shoulder belt241is also arranged to extend through a first shoulder belt-receiving slot181formed in head cradle40of headrest18as suggested inFIG. 5and through a first shoulder belt-receiving slot61formed in slidable cradle-retainer plate60of headrest18as suggested inFIGS. 2,6, and11.

A second shoulder belt242included in child-restraint harness14is arranged to extend through second belt-travel channel32as suggested inFIG. 5. Second shoulder belt142is also arranged to extend through a second shoulder belt-receiving slot182formed in head cradle40of headrest18as suggested inFIGS. 5 and 12and through a second shoulder belt-receiving slot62formed in slidable cradle-retainer plate60of headrest18as suggested inFIGS. 2,6, and11.

Head cradle40of headrest18includes a harness-control panel43formed to include first and second belt-receiving slots181,182. A plate mount44is coupled to harness-control panel43and arranged to extend downwardly toward seat bottom23. Head cradle40also includes a first side wing41coupled to one side of harness-control panel43and a second side wing42coupled to another side of harness-control panel43as suggested inFIG. 5. Illustratively, a head of a child seated on juvenile seat12is positioned to lie between first and second side wings41,42on harness-control panel43.

Headrest18is mounted for up-and-down movement on seat back24of seat shell20. The first and second shoulder belt-receiving slots181,182of harness-control panel43of head cradle40and the first and second shoulder belt-receiving slots61,62formed in slidable cradle-retainer plate60are aligned with their companion belt-travel channels31,32formed in backrest30of seat back24as suggested inFIG. 5. Shoulder belt-receiving slots181,182formed in head cradle40and shoulder belt-receiving slots61,62formed in slidable cradle-retainer plate60operate to keep shoulder belts241,242positioned at an appropriate height that corresponds to the vertical position of headrest18relative to seat back24.

Child-restraint harness14is used to restrain a child sitting on seat shell20. Child-restraint harness14in an illustrative embodiment is configured to include shoulder belts241,242, a crotch belt243, and thigh belts (not shown). Belt-travel channels31,32formed in backrest30allow shoulder belts241,242to move with headrest18along the length of seat back24between raised and lowered positions.

Headrest-height controller19is included in juvenile seat12and is shown diagrammatically inFIG. 1. Headrest-height controller19is configured and arranged to vary the height of headrest18above seat bottom23. An illustrative headrest-height controller19includes a headrest lock50and a headrest-lock release51.

Headrest lock50comprises a movable headrest-retainer rod52and one or more upwardly extending notched plates54coupled to seat back24. Each notched plate54is formed to include a series of companion rod-receiving notches56as suggested inFIG. 5.

Headrest-lock release51comprises a movable actuator handle58(seeFIGS. 2 and 6) and suitable linkage means59(seeFIGS. 9 and 10) interconnecting handle58and headrest-retainer rod52for selectively moving headrest-retainer rod52away from seat back24(at the option of a caregiver) to disengage rod-receiving notches56to free headrest18to be moved up or down on seat back24between raised and lowered positions in response to movement of actuator handle58relative to seat back24of seat shell20by a caregiver. Whenever headrest-retainer rod52is deposited by headrest-lock release51into rod-receiving notches56, headrest18is retained in a selected stationary position above seat bottom23of seat shell20.

Reference is hereby made to U.S. application Ser. No. 12/726,128, filed on Mar. 17, 2010, which reference is hereby incorporated in its entirety therein, for disclosures relating to headrest-height controllers. In an illustrative process, a caregiver can operate headrest-height controller19to unlock and lock headrest18so as to change the height of headrest18above seat bottom23. A caregiver can squeeze or otherwise move handle58toward seat shell20to cause linkage means59to move headrest-retainer rod52relative to notched plates54and cradle-retainer plate60to disengage notches56formed in notched plates54. Then the caregiver can lift headrest18to a higher position on seat back24or drop headrest18to a lower position on seat back24and then release actuator handle58to allow linkage means59to move (under, e.g., a spring force) to place headrest-retainer rod52in another of the notches56corresponding to a selected height above seat bottom23.

The slidable cradle-retainer plate60of headrest18is configured and arranged to assist in transferring loads applied to child-restraint harness14by a child70seated in juvenile seat12to first and second stiffener beams121,122of juvenile seat12during exposure of a vehicle72having a passenger seat74carrying juvenile seat12to an external impact force76as suggested inFIG. 11. During such an event, relative movement of the seated harnessed child70and juvenile seat causes, in series (1) a load L1to be applied by child70to first and second shoulder belts241,242; (2) a load L2to be applied by belts241,242to slidable cradle-retainer plate60of headrest18; (3) a load L3to be applied by slidable cradle-retainer plate60to seat shell20; and (4) a load L4to be applied by seat shell20to first and second stiffener beams121,122as suggested diagrammatically inFIG. 11. As such, the rigidifying structures (e.g., first and second stiffener beams121,122) carry loads applied to juvenile seat12during exposure of juvenile seat12to an external impact force76.

As shown inFIG. 6, slidable cradle-retainer plate60of headrest18includes a central bed600formed to include first and second belt-receiving slots61,62and first and second Z-shaped load-transfer flanges601,602. First Z-shaped load-transfer flange601is coupled to one side of central bed600and arranged to mate with and slide on a complementary companion first Z-shaped load-transfer rail201included in seat shell20and arranged to lie next to first rib221as suggested inFIGS. 9 and 10. Second Z-shaped load-transfer flange602is coupled to an opposite side of central bed600and arranged to mate with and slide on a complementary companion second Z-shaped load-transfer rail202included in seat shell20and arranged to lie next to second rib221as suggested inFIGS. 9 and 10.

The location of slidable cradle-retainer plate60between first and second ribs221,222and stiffener beams121,122anchored in beam-receiver channels21,22formed in ribs221,222is shown, for example, inFIG. 10. Also, mating engagement of slidable cradle-retainer plate60with first and second Z-shaped load-receiver rails201,202included in seat shell20is shown inFIGS. 8,9, and10. A diagrammatic perspective view provided inFIG. 11shows several of the components included in child restraint10and suggests that loads generated by movement of a child70seated and harnessed on juvenile seat12during exposure of a vehicle72carrying juvenile seat12will be transferred by child-restraint harness14, slidable cradle-retainer plate60, and seat shell20to first and second stiffener beams121,122of the rigidified juvenile seat12.

Child restraint10includes a juvenile seat12and a rigidifying truss120as shown, for example, inFIGS. 1 and 5. Juvenile seat12includes a seat shell20formed to include first and second beam-receiver channels21,22. Rigidifying truss120includes a first stiffener beam121located in first beam-receiver channel21and coupled to seat shell20to rigidify a first side of seat shell20and a separate second stiffener beam122located in second beam-receiver channel22and coupled to seat shell20to lie in spaced-apart relation to first stiffener beam121and to rigidify an opposite second side of seat shell20as suggested inFIGS. 1 and 5.

Seat shell20includes a seat bottom23and a seat back24extending upwardly from seat bottom23as suggested inFIGS. 1 and 5. Seat bottom23is formed to include a bottom section21a,22aof each of first and second beam-receiver channels21,22as shown inFIG. 5. Seat back24is formed to include a back section21b,22bof each of first and second beam-receiver channels21,22as shown inFIG. 5.

Each of first and second stiffener beams121,122is substantially J-shaped as shown, for example, inFIG. 5. First stiffener beam121includes a forwardly extending first blade121L located in bottom section21aof first beam-receiver channel21and an upwardly extending first handle121U coupled to a rear end of first blade121L and located in back section21bof first beam-receiver channel21as suggested inFIG. 5. Second stiffener beam122includes a forwardly extending second blade122L located in bottom section22aof second beam-receiver channel22and an upwardly extending second handle122U coupled to a rear end of second blade122L and located in back section22bof second beam-receiver channel22as suggested inFIG. 5.

Seat bottom23includes a seat pad28located between bottom sections121L,122L of first and second beam-receiver channels21,22as shown, for example, inFIG. 5. Seat pad28is formed to include a crotch belt-receiving slot243a,243bconfigured to provide means for receiving therein a crotch belt243included in a child-restraint harness14coupled to seat shell20as suggested inFIG. 5.

Seat shell20further includes a first side-wing panel26coupled to one side of seat bottom23and a second side-wing panel27coupled to an opposite side of seat bottom23as shown inFIG. 5. Bottom section21aof first beam-receiver channel21is arranged to lie between first side-wing panel26and seat pad28. Bottom section22aof second beam-receiver channel22is arranged to lie between seat pad28and second side-wing panel27.

Seat back24includes a backrest30located between back sections21b,22bof first and second beam-receiver channels21,22as shown, for example, inFIG. 5. Backrest30is formed to include slot means31,32for receiving therein first and second shoulder belts241,242included in a child-restraint harness14coupled to seat shell20. Back section21bof first beam-receiver channel21is arranged to lie between first side-wing panel26and backrest30. Back section22bof second beam-receiver channel22is arranged to lie between backrest30and second side-wing panel27.

Seat pad28is arranged to underlie a child seated on seat shell20. Seat pad28includes an upwardly facing surface arranged to provide means for supporting buttocks of a child seated on seat pad28.

Backrest30is arranged to extend upwardly from seat pad28to lie behind a child seated on seat shell20. Backrest30includes a forwardly facing surface arranged to provide means for supporting a back of a child seated on seat pad28.

Seat shell20also includes first and second ribs221,222as shown, for example, inFIGS. 2,5, and6. First rib221is coupled to seat pad28and backrest30and formed to include first beam-receiver channel21. Second rib222is coupled to seat pad28and backrest30and formed to include second beam-receiver channel22.

Each of first and second ribs221,222includes a lower rib portion221L,222L arranged to extend downwardly away from the upwardly facing surface of seat pad28to locate a bottom section21a,22bof each of first and second beam-receiver channels21,22below the upwardly facing surface of seat pad28as suggested inFIG. 5. Each of first and second ribs221,222includes an upper rib portion221U,222U arranged to extend rearwardly away from the forwardly facing surface of first and second beam-receiver channels21,22to locate a back section21b,22bof each of first and second beam-receiver channels21,22behind the forwardly facing surface of backrest30as suggested inFIG. 5.

Seat pad28is located between lower rib portions221L,222L of first and second ribs221,222as shown inFIG. 5. Backrest30is located between upper rib portions221U,222U of first and second ribs221,222as shown inFIG. 5.

Seat shell20has a front side20F formed to include a first aperture321opening into first beam-receiver channel21and a second aperture322opening into second beam-receiver channel22as shown inFIG. 5. Seat shell20also has an oppositely facing rear side20R coupled to first and second ribs221,222as suggested inFIGS. 2 and 6. Each of first and second stiffener beams221,222includes a blade arranged to extend alongside seat pad28and a handle arranged to extend upwardly away from the blade alongside backrest30as suggested inFIG. 5.

Child restraint10further includes a child-restraint harness14associated with the seat shell20as suggested inFIG. 5. Juvenile seat12further includes an adjustable headrest18including a cradle-retainer plate60mounted for up-and-down movement on a rearwardly facing surface of backrest30in a plate-receiver channel220(seeFIGS. 2,6, and9) provided between first and second ribs221,222to raise and lower first and second shoulder belts241,242included in child-restraint harness14and coupled to slidable cradle-retainer plate60. Adjustable headrest18further includes a head cradle40arranged to lie above seat pad28to support the head of a child seated on seat pad28as suggested inFIGS. 1 and 5and coupled to cradle-retainer plate60to move up and down therewith relative to backrest30as suggested inFIGS. 5 and 10.

Backrest30is formed to include first and second belt-receiver slots31,32as shown inFIG. 5. First belt-receiving slot31is located between first and second ribs221,222and arranged to receive first shoulder belt241therein during up-and-down movement of cradle-retainer plate60relative to backrest30. Second belt-receiver slot32is located between first belt-receiver slot31and second rib222and arranged to receive second shoulder belt242therein during up-and-down movement of cradle-retainer plate60relative to backrest30.

Cradle-retainer plate60includes first and second load-transfer flanges601,602as suggested inFIGS. 7,8, and10. First load-transfer flange601is arranged to slide in mating engagement on first load-receiver rail201during up-and-down movement of cradle-retainer plate60relative to backrest30to provide first means for transferring a load applied to first shoulder belt241by a child seated on seat pad28to first stiffener beam221during exposure of a vehicle having a passenger seat carrying juvenile seat12to an external impact force. Second load-transfer flange602is arranged to slide in mating engagement on second load-receiver rail202during up-and-down movement of cradle-retainer plate60relative to backrest30to provide second means for transferring a load applied to second shoulder belt242by a child seated on seat pad28to second stiffener beam222during exposure of a vehicle having a passenger seat carrying juvenile seat12to an external impact force.

Seat shell20has a front side20F arranged to face toward a child seated in seat shell20as suggested inFIG. 1. Front side20F is formed to include a first aperture321opening into first beam-receiver channel21and a second aperture322opening into second beam-receiver channel22as shown inFIG. 5. Seat bottom23is formed to include a portion of each of first and second apertures321,322. Seat back24is formed to include a portion of each of first and second apertures321,322.