Leg support for a vehicle seat

An occupant support may include a seat bottom and a seat back coupled to the seat bottom. In some embodiments, a leg support system is coupled to the seat bottom and configured to support an occupant's leg when in an extended position.

BACKGROUND

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

SUMMARY

According to the present disclosure, a vehicle includes a vehicle body defining a cabin and a plurality of occupant supports arranged in the cabin. The cabin is separated into a front section and one or more rear sections. The rear section includes at least one rear occupant support.

In illustrative embodiments, the rear occupant support is arranged to lie within a passenger compartment. The passenger compartment extends from the rear section of the cabin to the front section of the cabin. The passenger compartment is configured to provide more space for a passenger seated on the rear occupant support so that the passenger can fully extend his or her legs and has accessible storage space for personal belongings to provide a more comfortable experience for the passenger.

In illustrative embodiments, a passenger-comfort module is provided in the passenger compartment to increase comfort for the occupant on the rear occupant support. The passenger-comfort module includes a removable lumbar support and a leg support system that cooperate to provide a reclining effect for the occupant. The leg support system includes a first leg support coupled to the rear occupant support and a second leg support mounted on tracks in front of the rear occupant support. The tracks may have previously been used to mount a front occupant support to the vehicle.

DETAILED DESCRIPTION

An over-the-road vehicle10, in accordance with the present disclosure, is shown inFIG. 1. The vehicle10includes a vehicle body12that defines a cabin14of the vehicle10and a plurality of occupant supports16arranged to lie within the cabin14. A portion of the cabin14provides a passenger compartment18which is sized to increase comfort for a passenger being transported in the vehicle10. Situated within the passenger compartment18is an occupant-comfort module20that is configured to support portions of the occupant to improve comfort and an overall experience while traveling within the vehicle10. A second embodiment of an occupant-comfort module720is shown inFIG. 9.

The cabin14of the vehicle10is divided into one or more rear sections22and a forward section24. The passenger compartment18may be greater than or equal to about half of a total cumulative volume of the cabin14. The rear section22contains at least one rear occupant support28to support a passenger for transportation in the vehicle10. The forward section24contains only one front occupant support26. The front occupant support26is arranged forward of the rear occupant support28and is laterally offset from the rear occupant support so that the passenger compartment18extends from the rear section22to the forward section unobstructed by any front occupant support26. The only occupant support16within the passenger compartment18is a rear occupant support28so that the occupant can fully extend his or her legs and is provided with increased storage space in the passenger compartment18so that personal items are accessible by the passenger during transportation. The forward section24may be a front row of the vehicle or a middle row of the vehicle if the vehicle has more than two rows of occupant supports.

The occupant-comfort module20is configured to enhance comfort for the passenger seated on the rear occupant support28in the passenger compartment18as shown inFIG. 1. The occupant-comfort module20includes a removable lumbar support30and a leg support system32. The removable lumbar support30is configured to improve posture by engaging the occupant's lower back so that the occupant's spine is urged to an S-shape. The removable lumbar support30may cause the passenger's pelvic region and legs to be shifted forward relative to the occupant support such that the occupant's legs have less contact with the occupant support than they would absent the removable lumbar support30. The leg support system32is configured to engage portions of the passenger's legs to increase overall support and comfort for the passenger.

The removable lumbar support30and the leg support system32may cooperate to provide a reclining effect on the passenger without moving any portion of the occupant support28. Such an effect may be beneficial when used with rear-row occupant supports that have less functionality than front-row occupant supports, for example, when the rear-row occupant support is positioned against a rear panel45of the vehicle10and cannot recline due to this arrangement. Since the rear occupant support28is positioned behind the front-row occupant support26, privacy is also increased for the passenger.

The leg support system32includes a first leg support34coupled to a front end36of the rear occupant support28and a second leg support38spaced apart from the rear occupant support28and the first leg support34as shown inFIG. 1. The first leg support34is mounted to the front end36of the rear occupant support28to support the passenger's thighs and/or calves. The second leg support38is mounted to a floor40of the vehicle10in front of the rear occupant support28to support the occupants feet.

The first leg support34may be a stationary structure or may be mounted to the front end36of the rear occupant support28for pivotable movement relative to the occupant support28about a pivot axis42to raise and lower the first leg support34. The first leg support34may also be adjustable in length to accommodate passengers of different sizes. An example of a leg support suitable for use as the first leg support34in the illustrative embodiment is shown and described in U.S. Pat. No. 10,513,212, issued Dec. 24, 2019 to Faurecia Automotive Seating, LLC of Auburn Hills, Mich., which is expressly incorporated herein in its entirety for the purpose of describing a leg support mounted to an occupant support.

The second leg support38is mounted to tracks44located in front of the rear occupant support28in the forward section24as shown inFIG. 1. The tracks44may have been used to mount a front-row occupant support to the floor40of the vehicle10which the second leg support38has taken then place of. The second leg support38is slidable forward and backward along the tracks44and may be locked in place at any point along a length of the tracks44to fit passengers of different sizes. The location of the second leg support38relative to a front panel or dash56of the vehicle10provides a storage space54that can be used to store one or more of the passenger's items such as a travel bag55. The passenger's items in the storage space54are accessible by the passenger when desired as opposed to being stored in an inaccessible location such as a trunk of the vehicle10.

The second leg support38includes a footrest46, a first mount48, and a second mount50as shown inFIG. 1. The footrest46is a flat panel that is arranged at an angle52relative to the floor40of the vehicle10. The footrest46is coupled at each end to the first mount48and the second mount50, respectively. The first and second mounts48,50are coupled to an associated track44that extends along the floor40to fix the footrest46in position relative to the rear occupant support28.

The angle52is inclined so that the footrest46extends outwardly away from the rear occupant support28as shown inFIG. 1. The footrest46provides a platform for the passenger to use to counter act inertial forces experienced by the passenger during vehicle braking thereby increasing safety of the passenger in the vehicle10. The footrest46and/or each mount48,50may be adjustable, in some embodiments, to change the incline angle52of the footrest46relative to the floor40of the vehicle10. The angle52may be within a range of about 90 degrees to about 0 degrees relative to the floor40.

In the illustrative embodiment, the vehicle10is retrofitted with the occupant-comfort module20according to a process100of providing and using the occupant-comfort module20as shown inFIG. 2. The process100may include a step102of providing the vehicle10including the cabin14. The cabin14may house a plurality of occupant supports16including a first occupant support28and a second occupant support (not shown) directly in front of the first occupant support28. The second occupant support may be removed from the vehicle10at a step104thereby exposing the tracks44that previously secured the second occupant support to the floor40of the vehicle10. With the second occupant support removed, the passenger compartment is established which allows a passenger seated in the first occupant support28to fully extend their legs for greater comfort. In some embodiments, steps102and104may be omitted if the vehicle10is specifically designed to not include a second occupant support directly in front of the first occupant support28.

The process100may further include several steps of attaching the occupant-comfort module20to the first occupant support28and the vehicle10. The process may include a step106of mounting the first leg support34to the first occupant support28. The first leg support may be factory installed on the first occupant support28or installed at a later time. The process100may further include a step108of mounting the second leg support38to the tracks44where the second occupant support was located prior to being removed at step104. The removable lumbar cushion may also be coupled to the first occupant support28at a step110.

Once the occupant-comfort module20is attached to the first occupant support28and the vehicle10, the process100may include steps of using the occupant-comfort module20. The first and second leg supports34,38may be adjusted to fit a particular occupant at step112. The step112of adjusting the occupant-comfort module20may include raising or lowering the first leg support34and sliding the second leg support38forward or backward. One or more accessories60may be coupled to the first or second leg supports34,38at step114. The accessories60may include a table62, a monitor64, a privacy screen66, or any other type of accessory that increases comfort for the passenger in the passenger compartment18as shown inFIG. 1.

The first leg support34in the illustrative embodiment is removable from the rear occupant support28as suggested inFIG. 3. The first leg support34includes a cushion70, a mount flange72, and a retainer bracket74. The cushion70is configured to support the thigh and/or calf of the passenger to increase comfort for the passenger. The mount flange72is coupled to the cushion70and extends downwardly from the cushion70. The retainer bracket74is configured to be coupled to a frame structure76of the rear occupant support28. The mount flange72is sized to fit between the retainer bracket74and the frame structure76to mount the first leg support34to the rear occupant support28. Once mounted to the rear occupant support28the first leg support34increases a length of the occupant support28and supports the passenger's legs in an extended position for greater comfort.

A second embodiment of a first leg support234is shown inFIG. 4. The leg support234is similar to the first embodiment of the leg support34shown inFIGS. 1 and 3and similar reference numbers in the200series are used to describe common features between leg support34and leg support234. Accordingly, the disclosure of leg support34is incorporated by reference for leg support234and differences between leg support34and leg support234are described below.

Leg support234includes a cushion270, a fixed mount272, and a ratchet system275as shown inFIG. 4. The cushion270is configured to pivot relative to the fixed mount272between a storage position and an extended position as suggested inFIG. 4. The fixed mount272is coupled to a frame structure276of the rear occupant support28to secure the leg support234to the rear occupant support28. The ratchet system275controls movement of the cushion270relative to the fixed mount272by allowing upward pivoting of the cushion270from the storage position to the extended position. The ratchet system275allows the cushion270to be locked at any orientation between the storage position and the extended position. The ratchet system275blocks downward pivoting of the cushion270relative to the fixed mount272until the cushion270is pulled upwardly past the fully extended position, thereby releasing the ratchet system275so that the cushion270can return to the storage position.

A third embodiment of a first leg support334is shown inFIG. 5. The leg support334is similar to the second embodiment of the leg support234shown inFIG. 4and similar reference numbers in the300series are used to describe common features between leg support234and leg support334. Accordingly, the disclosure of leg support234is incorporated by reference for leg support334and differences between leg support234and leg support334are described below.

Leg support334includes a cushion370, a fixed mount372, and a plurality of inflatable bladders377as shown inFIG. 5. The cushion370is configured to pivot relative to the fixed mount372between a storage position and an extended position as suggested inFIG. 5. The fixed mount372is coupled to a frame structure376of the rear occupant support28to secure the leg support334to the rear occupant support28. The plurality of inflatable bladders377controls movement of the cushion370relative to the fixed mount372by pushing the cushion370to pivot upwardly from the storage position to the extended position when being inflated and allowing the cushion370to pivot downwardly when being deflated. Inflation of the bladders377may be stopped to lock the cushion370at any orientation between the storage position and the extended position.

A fourth embodiment of a first leg support434is shown inFIG. 6. The leg support434is similar to the second embodiment of the leg support234shown inFIG. 4and similar reference numbers in the400series are used to describe common features between leg support234and leg support434. Accordingly, the disclosure of leg support234is incorporated by reference for leg support434and differences between leg support234and leg support434are described below.

Leg support434includes a cushion470, a fixed mount472, and an adjustment system478as shown inFIG. 6. The cushion470is configured to pivot relative to the fixed mount472between a storage position and an extended position as suggested inFIG. 6. The fixed mount472is coupled to the rear occupant support28to secure the leg support434to the rear occupant support28. The adjustment system478is configured to block movement of the cushion470from pivoting downward. The adjustment system478includes a support rod479and a plurality of grooves480formed in an underside of the cushion470. The support rod479is sized to fit in one of the grooves480to hold the cushion in an extended position. The support rod479may be relocated to another groove480to change the orientation of the cushion470between the storage position and the extended position.

A fifth embodiment of a first leg support534is shown inFIG. 7. The leg support534is similar to the first embodiment of the leg support34shown inFIGS. 1 and 3and similar reference numbers in the500series are used to describe common features between leg support34and leg support534. Accordingly, the disclosure of leg support34is incorporated by reference for leg support534and differences between leg support34and leg support534are described below.

Leg support534includes a cushion570and a retainer system581as shown inFIG. 7. The cushion570is configured to support a passenger's legs and extends an overall length of the rear occupant support28. The retainer system581is configured to retain the cushion570to a frame structure576of the rear occupant support28. The retainer system581includes a first magnetic element582coupled to the frame structure576and a second magnetic element583coupled to the cushion570. The cushion570may be separated from the rear occupant support28by applying force to release the first and second magnetic elements582,583.

A sixth embodiment of a first leg support634is shown inFIG. 8. The leg support634is similar to the fourth embodiment of the leg support434shown inFIG. 6and similar reference numbers in the600series are used to describe common features between leg support434and leg support634. Accordingly, the disclosure of leg support434is incorporated by reference for leg support634and differences between leg support434and leg support634are described below.

Leg support634includes a cushion670, a fixed mount672, and an over-center linkage system684as shown inFIG. 8. The cushion670is configured to pivot relative to the fixed mount672between a storage position and an extended position as suggested inFIG. 8. The fixed mount672is coupled to the rear occupant support28to secure the leg support634to the rear occupant support28. The over-center linkage system684is configured to block the cushion670from pivoting downward once it has reached the extended position. Application of a force on the over-center linkage system684from beneath the cushion670allows the cushion to return to the storage position.

A second embodiment of an occupant-comfort module720for use in a vehicle710is shown inFIG. 9. The occupant-comfort module720is similar to the first embodiment of the occupant-comfort module20shown inFIG. 1and similar reference numbers in the700series are used to describe common features between occupant-comfort module20and occupant-comfort module720. Accordingly, the disclosure of occupant-comfort module20is incorporated by reference for occupant-comfort module720and differences between occupant-comfort module20and occupant-comfort module720are described below.

The occupant-comfort module720is configured to enhance comfort for the passenger seated on the rear occupant support728in the passenger compartment718as shown inFIG. 9. The occupant-comfort module720includes a removable lumbar support730and a leg support system732. The removable lumbar support730is configured to improve posture by engaging the occupant's lower back so that the occupant's spine is urged to an S-shape. The removable lumbar support730may cause the passenger's pelvic region and legs to be shifted forward relative to the occupant support such that the occupant's legs have less contact with the occupant support than they would absent the removable lumbar support730. The leg support system732is configured to engage portions of the passenger's legs to increase overall support and comfort for the passenger.

The removable lumbar support730and the leg support system732may cooperate to provide a reclining effect on the passenger without moving any portion of the occupant support728. Such an effect may be beneficial when used with rear-row occupant supports that have less functionality compared to front-row occupant supports, for example, when the rear-row occupant support is positioned against a rear panel745of the vehicle710and cannot recline due to this arrangement. Since the rear occupant support728is positioned behind the front-row occupant support726, privacy is also increased for the passenger.

The leg support system732includes a first leg support734coupled to a front end736of the rear occupant support728and a second leg support738spaced apart from the rear occupant support728and the first leg support734as shown inFIG. 9. The first leg support734is mounted to the front end736of the rear occupant support728to support the passenger's thighs and/or calves. The second leg support738is mounted to a floor740of the vehicle710in front of the rear occupant support728to support the occupants feet.

The first leg support734may be a stationary structure or may be mounted to the front end736of the rear occupant support728for pivotable movement relative to the occupant support728about a pivot axis742to raise and lower the first leg support734. The second leg support738is mounted to tracks744located in front of the rear occupant support728in the front section724as shown inFIG. 9. The tracks744may have been used to mount a front-row occupant support to the floor740of the vehicle710which the second leg support738has taken then place of. The second leg support738is slidable forward and backward along the tracks744and may be locked in place at any point along a length of the tracks744to fit passengers of different sizes. The location of the second leg support738relative to a front panel or dash756of the vehicle710provides a storage space754that can be used to store one or more of the passenger's items such as a travel bag755. The passenger's items in the storage space754are accessible by the passenger when desired as opposed to being stored in an inaccessible location such as a trunk of the vehicle710.

The second leg support738includes a calf rest746, a first mount748and a second mount750as shown inFIG. 9. The calf rest746allows a passenger seated in rear occupant support728to rest their calves above the floor740in a fully extended position for greater comfort. The calf rest746is coupled at each end to the first mount748and the second mount750, respectively. The first and second mounts748,750are coupled to an associated track744that extends along the floor740to fix the calf rest746in position relative to the rear occupant support728.

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

Clause 1. An over-the-road vehicle comprises a vehicle body defining a cabin, the cabin comprising a forward section, a rear section arranged to lie behind the forward section relative to a longitudinal axis of the vehicle, and at least one passenger compartment that is defined by portions of both the forward section and the rear section.

Clause 2. The vehicle of clause 1, any other clause or any suitable combination of clauses, further comprising a plurality of occupant supports including a forward occupant support arranged to lie in the forward section of the cabin and a rear occupant support offset from the front occupant support relative to a lateral axis of the vehicle and arranged to lie in the rear section of the cabin and in the passenger compartment such that the passenger compartment includes only the rear occupant support out of the plurality of occupant supports.

Clause 3. The vehicle of clause 2, any other clause or any suitable combination of clauses, further comprising a passenger-comfort module including a removable lumbar cushion coupled to the rear occupant support and a leg support system including a first leg support coupled to a front end of the rear occupant support in the rear section of the cabin and a second leg support arranged to lie in the forward section of the cabin.

Clause 4. The vehicle of clause 3, any other clause or any suitable combination of clauses, wherein the second leg support is mounted to tracks and arranged to lie in spaced-apart relation to the first leg support so that the occupant may support their legs in a fully-extended position outwardly away from the occupant support on the second leg support.

5. The vehicle of clause 4, any other clause or any suitable combination of clauses, wherein the second leg support is spaced apart from a front panel of the vehicle to provide a storage space there between.

6. The vehicle of clause 4, any other clause or any suitable combination of clauses, wherein the rear occupant support directly contacts a rear panel of the vehicle and the removable lumbar cushion and the leg support system cooperate to provide a reclining effect for the occupant.

7. The vehicle of clause 6, any other clause or any suitable combination of clauses, wherein the first leg support extends an overall length of the rear occupant support to increase contact areas with the occupant's legs as a result of the occupant's pelvic region being moved forward by the removable lumbar support.

8. The vehicle of clause 3, any other clause or any suitable combination of clauses, wherein the passenger compartment is greater than or equal to about half of a total cumulative volume of the cabin.

9. An occupant-comfort module for an over-the-road vehicle, the occupant comfort module comprises an occupant support adapted to lie in a rear section of a vehicle,

10. The occupant-comfort module of clause 9, any other clause or any suitable combination of clauses, further comprising a removable lumbar support coupled to the occupant support,

Clause 11. The occupant-comfort module of clause 10, any other clause or any suitable combination of clauses, further comprising a first leg support coupled to a forward end of the occupant support and adapted to engage at least one of a thigh and a calf of an occupant seated in the occupant support, and

Clause 12. The occupant-comfort module of clause 11, any other clause or any suitable combination of clauses, further comprising a second leg support adapted to be mounted to tracks on a floor of a vehicle and arranged to lie in spaced-apart relation to the first leg support so that the occupant may support their legs in a fully-extended position outwardly away from the occupant support on the second leg support.

13. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion, a mount flange coupled to the cushion and a retainer bracket coupled to the occupant support and the mount flange and the retainer bracket are slidably engaged with one another so that the cushion is separable from the occupant support.

14. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion, a fixed mount, and a ratchet system configured to control pivotable movement of the cushion relative to the fixed mount.

15. The occupant-comfort module of 12, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion, a fixed mount, and a plurality of inflatable bladder arranged between the fixed mount and the cushion and configured to push the cushion away from the fixed mount when inflated to raise an occupant's legs.

16. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion, a fixed mount, and an adjustment system including a support rod and a plurality of grooves formed in an underside of the cushion to receive the support rod and support the cushion in an extended position.

17. The occupant-comfort module of clause 15, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion and a retainer system including a first magnetic element coupled to the occupant support and a second magnetic element coupled to the cushion.

18. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the first leg support includes a cushion, a fixed mount, and an over-center linkage system configured to support the cushion in an extended position.

19. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the second leg support includes a footrest a first mount coupled to a first track and a second mount coupled to a second track and the footrest is arranged at an angle relative to the floor and is adjustable to vary the angle.

20. The occupant-comfort module of clause 12, any other clause or any suitable combination of clauses, wherein the second leg support includes a calf rest, a first mount coupled to a first track and a second mount coupled to a second track and the calf rest is configured to support the occupant's legs above the floor in the fully-extended position.

21. A method of providing an occupant comfort module in an over-the-road vehicle, the method comprises a step of removing an occupant support from the vehicle, the occupant support being second occupant support arranged forward of a first occupant support relative to a longitudinal axis of the vehicle prior to the step of removing.

22. The method of clause 21, any other clause or any suitable combination of clauses, further comprising a step of mounting a first leg support to a forward end of the first occupant support.

23. The method of clause 22, any other clause or any suitable combination of clauses, further comprising a step of mounting a second leg support to an attachment location where the second occupant support was mounted to the vehicle prior to the step of removing.

24. The method of clause 23, any other clause or any suitable combination of clauses, wherein the attachment location includes tracks and the second leg support is slidable forward and backward along the tracks.

25. The method of clause 24, any other clause or any suitable combination of clauses, wherein the first occupant support is arranged to lie in a passenger compartment that extends from a rear section of the vehicle to a front section of the vehicle unobstructed by any other vehicle seat in front of the first occupant support.

26. The method of clause 25, any other clause or any suitable combination of clauses, further comprising a step of mounting a removable lumbar cushion to the first occupant support and adjusting the first leg support and the second leg support so that the occupant's legs are supported after the occupant's pelvic region is shifted forward by the removable lumbar cushion.

27. The method of clause 25, any other clause or any suitable combination of clauses, further comprising the step of mounting an accessory to the first leg support or the second leg support, the accessory including at least one of a table, a monitor, and a privacy screen.