Shafted recliners dual decoupling system

An occupant support adapted for use in a vehicle includes a seat bottom coupled to a floor of the vehicle and a seat back configured to pivot about a seat-back pivot axis relative to the seat bottom between an upright position and a folded-forward position. The occupant support further includes a seat-motion controller configured to control movement of the seat back relative to the seat bottom.

BACKGROUND

The present disclosure relates to occupant supports, and particularly to movable occupant supports. More particularly, the present disclosure relates to occupant supports with reclining seat backs for use in vehicles.

SUMMARY

According to the present disclosure, an occupant support includes a seat bottom, a seat back, and seat-motion controller. The seat back is coupled to the seat bottom for movement about a seat-back pivot axis relative to seat bottom. The seat-motion controller is configured to control movement of seat back about seat-back pivot axis relative to seat bottom.

In illustrative embodiments, the seat-motion controller includes a dual-recliner actuator that interconnects right and left recliners. The dual-recliner actuator provides means for changing the right and left recliners from a locked arrangement to an unlocked arrangement to allow pivotable movement of the seat back about the seat-back pivot axis. The dual-recliner actuator also provides means for changing the right and left recliners between the locked arrangement and the unlocked arrangement so that neither recliner blocks the other from reaching the locked arrangement.

In illustrative embodiments, the dual-recliner actuator includes a connector tube, an actuator lever coupled to the connector tube, a pair of lost-motion inserts, and a lever return spring. The connector tube interconnects the left recliner and the right recliner. The actuator lever is configured to move the connector tube from a locked position to a freed position to unlock right and left recliner locks and allow movement of the seat back about the seat back pivot axis. The actuator lever is biased by a torsion spring toward the locked position to maintain each recliner lock in the locked arrangement until the actuator lever is actuated as well as to neutralize an actuator lever inertial unlocking.

A left lost-motion insert is coupled to a left shaft and is moveable relative to the connector tube about the seat-back pivot axis. A right lost-motion insert is coupled to a right shaft and movable relative to the connector tube and the right lost-motion insert about the seat-back pivot axis. The left and right lost-motion inserts are configured to provide a lost-motion driving connection between the right recliner lock and the left recliner-lock to control unlocking and relocking of each recliner lock.

DETAILED DESCRIPTION

An occupant support10in accordance with the present disclosure is adapted for use in a vehicle as shown inFIGS. 1-3. The occupant support10includes a seat bottom12, a seat back14, and seat-motion controller16as shown inFIGS. 1-3. The seat back14is coupled to the seat bottom12for movement about a seat-back pivot axis15relative to seat bottom12. The seat-motion controller16is configured to provide means for controlling movement of seat back14about seat-back pivot axis15relative to seat bottom12. The seat-motion controller16includes a dual-recliner actuator22that interconnects right and left recliners18,20. The dual-recliner actuator22provides means for changing the right and left recliners18,20from a locked arrangement to an unlocked arrangement to allow pivotable movement of the seat back14about the seat-back pivot axis15as suggested inFIGS. 4A-4B. The dual-recliner actuator22also provides means for preventing the right and left recliners18,20from blocking each other from returning to the locked arrangement as suggested inFIGS. 4C-4D.

The seat-motion controller16includes right recliner18, left recliner20, and dual-recliner actuator22as shown inFIGS. 1-3. The right recliner18is arranged generally along a right side of the occupant support10when viewed from a perspective of an occupant seated on the occupant support10. The left recliner20is arranged generally along a left side of the occupant support10when viewed from the perspective of an occupant seated on the occupant support10. It should be noted that the right and left recliners18,20may be interchangeable. The dual-recliner actuator22extends along the seat-back pivot axis15and interconnects the right and left recliners18,20. The right and left recliners18,20are substantially similar to one another in the illustrative embodiment, however, in some embodiments the right and left recliners18,20may be different from one another.

The right and left recliners18,20interconnect the seat back14and the seat bottom12to allow movement of the seat back14about the seat-back pivot axis15as suggested inFIGS. 1 and 2. The right recliner18includes a right fixed flange24coupled to the seat bottom12, a right mobile flange26coupled to the seat back14, and a right recliner lock28. The right fixed flange24is configured to remain stationary relative to the seat bottom12as the seat back14moves about the seat-back pivot axis15. The mobile flange26is configured to move with the seat back14about the seat-back pivot axis15. The right recliner lock28may be actuated by the dual-recliner actuator22to change the right recliner lock28from a locked arrangement to an unlocked arrangement.

The left recliner20includes a left fixed flange30coupled to the seat bottom12, a left mobile flange32coupled to the seat back14, and a left recliner lock34as shown inFIGS. 1 and 2. The left fixed flange30, the left mobile flange32, and the left recliner lock34are substantially similar to right fixed flange24, the right mobile flange26, and the right recliner lock28of right recliner18and operate in the same manner. The right and left recliner locks28,34are configured to engage the mobile flanges26,32in the locked arrangement to block pivotable movement of the seat back14and the mobile flanges26,32about the seat-back pivot axis15. The right and left recliner locks28,34disengage to allow pivotable movement of the seat back about the seat-back pivot axis in the unlocked arrangement.

The right recliner lock28includes a right shaft36and the left recliner lock34includes a left shaft38. The right and left shafts36,38are engaged by the dual-recliner actuator22and may be actuated to change the right and left recliner locks28,34from the locked to the unlocked arrangement. The right and left recliner locks28,34may include movable components that are actuated thru rotation of the right and left recliner shafts36,38from the locked to the unlocked arrangement. The dual-recliner actuator22is configured to rotate each of the shafts36,38about the seat-back pivot axis15to change each of the recliner locks28,34from the locked arrangement to the unlock arrangement so that the seat back14is free to pivot relative to the seat bottom12.

The dual-recliner actuator22is configured to provide a lost-motion driving connection between the right recliner lock28and the left recliner-lock34as suggested inFIG. 2. Due to manufacturing tolerances and/or seat back twist, the right recliner shaft36and the left recliner shaft38may be arranged at different angular orientations relative to one another during relocking. This may cause the right recliner lock28and the left recliner lock34to change between the locked arrangement and the unlocked arrangement at different angular orientations. Absent the dual-recliner actuator22, the right or the left recliner lock28,34could prevent the other from returning to the locked arrangement due to the different angular orientations at which they return to the locked arrangement. The lost-motion driving connection provided by the dual-recliner actuator22allows each recliner lock28,34to change between the locked and unlocked arrangements so that neither recliner lock28,34blocks the other from returning to the locked arrangement.

The dual-recliner actuator22includes a connector tube40, an actuator lever42coupled to the connector tube40, and a pair of lost-motion inserts44,46as shown inFIGS. 2 and 3. The connector tube40interconnects the right recliner shaft36and the left recliner-shaft38. The actuator lever42is configured to move the connector tube40from a locked position (as shown inFIG. 4A), in which the right and left recliner locks28,34are in the locked arrangement, to a freed position (as shown inFIG. 4B), in which the right and left recliner locks28,34are in the unlocked arrangement. The actuator lever42is biased by a torsion spring43toward the locked position to maintain each recliner lock in the locked arrangement until the actuator lever42is actuated. A right lost-motion insert44is coupled to the right shaft36and is moveable relative to the connector tube40about the seat-back pivot axis15in both clockwise and counter-clockwise directions. A left lost-motion insert46is coupled to the left shaft34and movable relative to the connector tube40and the right lost-motion insert44about the seat-back pivot axis15in both clockwise and counter-clockwise directions. The right and left lost-motion inserts44,46are fixed to their respective shaft36,38to assume the same angular orientation as the shafts36,38as suggested inFIGS. 2 and 3.

The right and left lost-motion inserts44,46are sized relative to the connector tube40so that the connector tube40may assume an angular orientation that is different than both the right recliner lock28and the left recliner lock34as suggested inFIG. 2. The connector tube40includes a tube body50, a right lost-motion end52, and a left lost motion end54. The tube body50has a generally cylindrical cross-sectional shape. The right lost-motion end52defines a right insert-receiving space56that receives the right lost-motion insert44. The left lost-motion end54defines a left insert-receiving space58that is positioned in a direction opposite the right insert-receiving space56and receives the left lost-motion insert46.

The right and left insert-receiving spaces56,58of the connector tube40have a first cross sectional area while the right and left lost-motion inserts44,46have a second cross sectional shape that is less than the first cross sectional area. In the illustrative embodiment, the first cross sectional area and the second cross sectional shape are generally triangular shaped as shown inFIGS. 4A-4D. The difference in size and shape of the first cross sectional area compared to the second cross sectional shape permits rotation of the connector tube40relative to the right and left lost-motion inserts44,46within a predetermined range of rotation. Once the connector tube40has rotated past the predetermined range of rotation for each lost-motion insert44,46, the right-lost motion end52and the left lost-motion end54contact each respective lost-motion insert44,46as shown inFIGS. 4B and 4C. Further rotation of the connector tube40after the right and left lost-motion ends52,54contact the lost-motion inserts44,46will cause the right and left shafts to disengage so that the right and left recliner locks assume the unlocked arrangement. The predetermined range of rotation of the connector tube40relative to the right lost-motion insert44may be different compared to the predetermined range of rotation relative to the left lost-motion insert46depending on the angular orientation of the right shaft36compared to the left shaft38.

FIGS. 4A-4Dillustrate one example of an arrangement of the right and left lost-motion inserts44,46relative to the connector tube40. Each lost-motion insert44,46is shown relative to its corresponding lost-motion end52,54as the connector tube40is pivoted by the actuator lever42to move the right and left shafts36,38in an unlocking direction (clockwise direction), as shown inFIG. 4B, and a relocking direction (counter-clockwise direction), as shown inFIGS. 4C and 4D.

The right and left lost-motion inserts44,46are arranged within their corresponding lost-motion end52,54of the connector tube40inFIGS. 4A-4D. In the locked position, the actuator lever42is biased by the torsion spring43into contact with a stop41at a contact point61as shown inFIG. 4A. In this position, the right and left lost-motion inserts44,46are arranged at an orientation relative to the connector tube40that allows each lost motion insert44,46to rotate relative to the ends52,54of the connector tube40in both clockwise and counter-clockwise directions. Illustratively, the lost-motion inserts44,46are sized and arranged relative to the connector tube40to allow for a 4 degree rotation in the clockwise direction and a 22 degree rotation in the counter-clockwise direction before contacting the connector tube40. However, in other embodiments, any suitable degree of rotation in the clockwise and counter-clockwise directions may be used.

As the actuator lever42is moved to the freed position, the actuator lever disengages the stop41and rotates the connector tube40in the unlocking direction into contact with each lost-motion insert44,46as shown inFIG. 4B. The ends52,54of the connector tube40contact each respective lost-motion insert44,46at contact points60such that further rotation of the connector tube40in the unlocking direction moves the right and left shafts36,38with the connector tube40. This motion changes the right and left recliner locks28,34to the unlocked arrangement to allow pivotable movement of the seat back14about the axis15.

The actuator lever42and the connector tube40are biased in the relocking direction by the torsion spring43to automatically return the connector tube40to the locked position as suggested inFIGS. 4C and 4D. As the connector tube40is moved in the relocking direction, the ends52,54of the connector tube40move relative to the lost-motion inserts44,46until the ends contact the lost-motion inserts at a second set of contact points63. Further rotation of the connector tube40in the relocking direction moves the lost-motion inserts44,46and the shafts36,38with the connector tube40in the relocking direction until each recliner lock reaches the locked arrangement.

In some instances, manufacturing tolerances may result in one of the recliner locks returning to the locked arrangement before the other as suggested inFIG. 4D. The actuator lever42is in the locked position in contact with stop41and, illustratively, the right recliner lock28is in the locked arrangement while the left recliner lock34remains in the unlocked arrangement. Both lost-motion inserts44,46are allowed to rotate relative to the connector tube40in this position so that the left recliner lock34may be moved even with the actuator lever in the locked position to return the left recliner lock34to the locked arrangement. In one example, an external force on the seat back14causes additional movement of the left recliner lock34with the actuator lever42in the locked position to return the left recliner lock34to the locked arrangement. In this way, the dual recliner actuator22prevents each recliner lock from being blocked from returning to the locked arrangement.

Each lost-motion insert44,46includes a body62, a plurality of splines64, and a plurality of flex fingers66(also called arms66) as shown inFIGS. 5 and 6. Only lost-motion insert46is shown inFIGS. 5 and 6because lost-motion insert44is identical to lost-motion insert46. The body62has an external surface68that engages its respective end54of the connector tube40as described above. The body62also has an internal surface70defining a passageway71that receives the left shaft38as suggested inFIG. 5. The plurality of splines64are coupled to the internal surface70in mating arrangement with corresponding splines72on the shaft38. The plurality of splines64cooperate with the corresponding splines72on the shaft38to transmit torque between the lost-motion insert46and the shaft38. The plurality of arms66extend from the body62of the insert46toward the tube body50.

The lost-motion insert46is configured to slide onto the shaft38along a shaft axis39as shown inFIGS. 6 and 7. The lost-motion insert46is sized relative to the shaft38to provide a friction-interference fit between the lost-motion insert46and the shaft38as suggested inFIGS. 7-9. The plurality of flex fingers66are spaced apart from one another circumferentially around a tip of the shaft38. The plurality of flex fingers66each include an flex fingers body74and a projection76as shown inFIGS. 7 and 8. The flex fingers body74extends away from the body62of the insert46toward the tube body50. The projection76extends inwardly from the arm body74toward the shaft axis39and establishes a lost-motion insert stop. Each arm provides a compressive force on the shaft38when installed to form the friction-interference fit with the shaft38retain the insert46to the shaft38.

The body62of the lost-motion insert46has an inner diameter that is slightly greater than an outer diameter of the shaft38as shown inFIG. 9. The difference in diameters provides a small clearance gap80radially between the shaft38and the lost-motion insert46to accommodate size variations in the shaft38. A second clearance gap82is established axially between the body62of the lost-motion insert46and a flange84of the shaft38. The gap82accommodates length variations in the shaft38.

As discussed above, the lost-motion inserts44,46have a generally triangular shaped cross section provided by three projections86as shown inFIG. 10. Each lost-motion end52,54of the connector tube40includes three tip sections88interposed between three blocker sections90. The three projections86of the lost-motion inserts44,46point toward a respective tip section88. Each lost-motion insert44,46is movable relative to the connector tube40such that the projections86travel between adjacent blocker sections90within the predetermined range of motion92to provide the lost motion driving connection described above. Each lost-motion insert44,46contacts the blocker sections90as the connector tube40is rotated relative to the insert44,46to change right and left recliner locks28,34from the locked arrangement to the unlocked arrangement. In the illustrative embodiment, the predetermined range of motion is equal to about 26 degrees, however, any suitable range of motion may be used in other embodiments.

The shape of the lost-motion inserts44,46may vary as suggested inFIGS. 11 and 12. The shape of the lost-motion ends52,54of the connector tube40may also change to match the shape of the lost-motion inserts44,46and to provide the lost motion driving connection described above.

Another embodiment of a lost-motion insert244and a corresponding lost-motion end252is shown inFIG. 11. The lost-motion insert244includes four projections286. The lost motion end252includes four tip sections288interposed between four blocker sections290. The four projections286of the lost motion insert244point toward a respective tip section288. The lost-motion insert244is movable relative to the connector tube40such that the projections286travel between adjacent blocker sections290within a predetermined range of motion292to provide the lost motion driving connection described above. The lost-motion insert244contacts the blocker sections290as the connector tube40is rotated relative to the insert244to change right and left recliner locks28,34from the locked arrangement to the unlocked arrangement. In the illustrative embodiment, the predetermined range of motion292is equal to about 30 degrees, however, any suitable range may be used.

Another embodiment of a lost-motion insert344and a corresponding lost-motion end352is shown inFIG. 12. The lost-motion insert344includes a single projection386. The lost motion end352includes a single tip section388interposed between a pair of blocker sections390. The projection386of the lost motion insert344points toward the tip section388. The lost-motion insert344is movable relative to the connector tube40such that the projection386travels between the adjacent blocker sections390within a predetermined range of motion392to provide the lost motion driving connection described above. The lost-motion insert344contacts the blocker sections390as the connector tube40is rotated relative to the insert344to change right and left recliner locks28,34from the locked arrangement to the unlocked arrangement. In the illustrative embodiment, the predetermined range of motion392is equal to about 30 degrees, however, any suitable range may be used.

The following numbered clauses include embodiments that are contemplated and non-limiting:

Clause 1. An occupant support comprises a seat bottom and a seat back coupled to the seat bottom for pivotable movement about a seat-back pivot axis relative to the seat bottom.

Clause 2. The occupant support of clause 1, or any other suitable clause or combination of clauses, further comprising a seat-motion controller configured to control pivotable movement of the seat back relative to the seat bottom, the seat-motion controller including a right recliner with a right recliner-lock, a left recliner with a left recliner-lock, and a dual-recliner actuator configured rotate about an actuator pivot axis to change the right recliner-lock and the left recliner-lock from a locked arrangement where pivotable movement of the seat back about the seat-back pivot axis is blocked and an unlocked arrangement where pivotable movement of the seat back about the seat-back pivot axis is permitted.

Clause 3. The occupant support of clause 2, or any other suitable clause or combination of clauses, wherein the dual-recliner actuator is configured to provide a lost-motion driving connection between the right recliner-lock and the left recliner-lock that allows each recliner lock to move between the locked arrangement and the unlocked arrangement independently of one another so that neither recliner lock blocks the other recliner lock from returning to the locked arrangement.

Clause 4. The occupant support of clause 3, or any other suitable clause or combination of clauses, wherein dual-recliner actuator includes a connector tube that interconnects the right recliner-lock and the left recliner-lock, an actuator lever coupled to the connector tube, a right lost-motion insert coupled to the right recliner-lock and moveable relative to the connector tube, and a left lost-motion insert coupled to the left recliner-lock and movable relative to the connector tube.

Clause 5. The occupant support of clause 4, or any other suitable clause or combination of clauses, wherein connector tube includes a tube body with a generally cylindrical cross-sectional shape, a right lost-motion end defining a right insert-receiving space, and a left lost-motion end defining a left insert-receiving space opposite the right lost-motion end.

Clause 6. The occupant support of clause 5, or any other suitable clause or combination of clauses, wherein the right and left insert-receiving spaces have a first cross sectional area and the right and left lost-motion inserts have a second cross sectional shape that is less than the first cross sectional area.

Clause 7. The occupant support of clause 6, or any other suitable clause or combination of clauses, wherein the first cross sectional area and the second cross sectional shape are generally triangular shaped.

Clause 8. The occupant support of clause 4, or any other suitable clause or combination of clauses, wherein each lost-motion insert includes a body, a plurality of splines, and a plurality of flex fingers, the body having an external surface that engages the connector tube and an internal surface defining a passageway that receives a corresponding shaft, the plurality of splines coupled to the internal surface in mating arrangement with corresponding splines on the shaft.

Clause 9. The occupant support of clause 8, or any other suitable clause or combination of clauses, wherein the plurality of flex fingers form a friction-interference fit with the shaft.

Clause 10. An occupant support comprising a seat bottom, a seat back coupled to the seat bottom for movement about a seat-back pivot axis relative to the seat bottom to change an angle of the seat back relative to the seat bottom, and a seat-motion controller configured to control pivotable movement of the seat back relative to the seat bottom, the seat-motion controller including a right recliner with a right recliner-shaft, a left recliner with a left recliner-shaft, and a dual-recliner actuator configured to change the right and left recliner-shafts between a locked arrangement in which pivotable movement of the seat back about the seat-back pivot axis is blocked and a unlocked arrangement in which pivotable movement of the seat back about the seat-back pivot axis is allowed, wherein dual-recliner actuator includes a connector tube that interconnects the right recliner-shaft and the left recliner-shaft, an actuator lever coupled to the connector tube and configured to move the connector tube from a locked position to a freed position, a right lost-motion insert coupled to the right recliner-lock and moveable relative to the connector tube, and a left lost-motion insert coupled to the left recliner-lock and movable relative to the connector tube.

Clause 11. The occupant support of clause 10, or any other suitable clause or combination of clauses, wherein the actuator lever is coupled to a torsion spring to bias the connector tube toward the locked position.

Clause 12. The occupant support of clause 11, or any other suitable clause or combination of clauses, wherein connector tube includes a tube body with a generally cylindrical cross-sectional shape, a right lost-motion end defining a right insert-receiving space, and a left lost-motion end defining a left insert-receiving space opposite the right lost-motion end.

Clause 13. The occupant support of clause 12, or any other suitable clause or combination of clauses, wherein the right and left insert-receiving spaces have a first cross sectional area and the right and left lost-motion inserts have a second cross sectional shape with an area that is less than the first cross sectional area.

Clause 14. The occupant support of clause 13, or any other suitable clause or combination of clauses, wherein the first cross sectional area and the second cross sectional shape are generally triangular shaped.

Clause 15. The occupant support of clause 12, or any other suitable clause or combination of clauses, wherein each lost-motion insert includes a body, a plurality of splines, and a plurality of flex fingers, the body having an external surface that engages the connector tube and an internal surface defining a passageway that receives a corresponding shaft, the plurality of splines coupled to the internal surface in mating arrangement with corresponding splines on the shaft.

Clause 16. The occupant support of clause 15, or any other suitable clause or combination of clauses, the plurality of arms form a friction-interference fit with the shaft.

Clause 18. An occupant support comprising a seat bottom, a seat back coupled to the seat bottom for pivotable movement about a seat-back pivot axis relative to the seat bottom, and a seat-motion controller configured to control pivotable movement of the seat back relative to the seat bottom, the seat-motion controller including a right recliner arranged along a right lateral side of the seat back, a left recliner arranged along a left lateral side of the seat back, and a dual-recliner actuator that interconnects the right recliner and the left recliner and provides means for changing the right and left recliners between a locked arrangement and an unlocked arrangement so that neither recliner blocks the other from reaching the locked arrangement as the right and left recliners move from the unlocked arrangement to the locked arrangement.

Clause 19. The occupant support of clause 18, or any other suitable clause or combination of clauses, the right and left recliners each include a fixed flange coupled to the seat bottom, a mobile flange coupled to the seat back and configured to move relative to the fixed flange, and a recliner lock configured to block pivotable movement of the seat back in the locked arrangement and a allow pivotable movement of the seat back about the seat-back pivot axis in the unlocked arrangement.

Clause 20. The occupant support of clause 19, or any other suitable clause or combination of clauses, the dual-recliner actuator includes a connector tube interconnecting the right and left recliners and arranged at a right locking shaft angular orientation, a right lost-motion insert coupled to the recliner-lock of the right recliner and arranged at a left locking shaft angular orientation, and a left lost-motion insert coupled to the recliner-lock of the left recliner and arranged at a third angular orientation.

Clause 21. The occupant support of clause 20, or any other suitable clause or combination of clauses, wherein the right lost-motion insert and the left lost-motion insert are movable relative to one another and relative to the connector tube.

Clause 22. The occupant support of clause 20, or any other suitable clause or combination of clauses, wherein each lost-motion insert includes a body, a plurality of splines, and a plurality of flex fingers, the body having an external surface that engages the connector tube and an internal surface defining a passageway that receives a corresponding shaft, the plurality of splines coupled to the internal surface in mating arrangement with corresponding splines on the shaft.

Clause 23. The occupant support of clause 22, or any other suitable clause or combination of clauses, wherein the plurality of flex fingers form a friction-interference fit with the shaft.