Abstract:
A seat assembly is provided with a seat cushion and a pivotal seat back. Sensors are connected to the seat cushion and/or the seat back to detect a seating position. An actuator is connected to the seat cushion and/or the seat back for adjustment. A controller is configured to receive data from the plurality sensors, compare the data to determine if the occupant is seated evenly, and adjust the actuator to balance the occupant posture seating position. The controller is in electrical communication with an inflation device to inflate a first air bladder assembly in a thoracic region of the seat back. A second air bladder assembly oriented in a lumbar region, a sacrum region, and/or a scapular region of the seat back is inflated after initiating inflation of the first air bladder assembly for sequential posture alignment.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional application Ser. No. 62/009,585 filed Jun. 9, 2014, the disclosure of which is hereby incorporated in its entirety by reference herein. 
     
    
     TECHNICAL FIELD 
       [0002]    Various embodiments relate to adjustable seat assemblies. 
       BACKGROUND 
       [0003]    An adjustable seat assembly is illustrated and described in U.S. Pat. No. 5,758,924, which issued on Jun. 2, 1998 to Lear Corporation. 
       SUMMARY 
       [0004]    According to at least one embodiment, a seat assembly is provided with a seat cushion. A seat back is adapted to be pivotally mounted adjacent the seat cushion. A plurality of sensors is operably connected to at least one of the seat cushion and the seat back to detect a seating position of an occupant. An actuator is operably connected to at least one of the seat cushion and the seat back for adjustment at least one of a plurality of settings of the seat assembly. A controller is in electrical communication with the plurality of sensors and the actuator, and is configured to receive data from the plurality sensors, compare the data to determine if the occupant is seated evenly, and adjust the actuator to balance the occupant posture seating position. 
         [0005]    According to at least another embodiment, a seat assembly is provided with a seat back. A first air bladder assembly or a first series of multiple bladders is oriented in a thoracic region of the seat back. A second air bladder assembly or a second series of multiple bladders is oriented in at least one of a lumbar region, a sacrum region, and a scapular region of the seat back. An inflation device is in fluid communication with the first and second inflatable air bladder assemblies. A controller is in electrical communication with the inflation device. The controller is configured to operate the inflation device to inflate the first air bladder assembly. The controller is also configured to operate the inflation device to inflate the second air bladder assembly after initiating inflation of the first air bladder assembly. In embodiments, the method provides for sequential posture alignment. 
         [0006]    According to at least another embodiment, a computer-program product is embodied in a non-transitory computer readable medium that is programmed for automatically adjusting a seat assembly. The computer-program product includes instructions for receiving input indicative of measured pressure values from a plurality of sensors in a plurality of zones of a seat assembly. The data is compared to determine if the occupant is seated evenly. An actuator is adjusted to balance the occupant posture seating position. 
         [0007]    According to at least another embodiment, a computer-program product is embodied in a non-transitory computer readable medium that is programmed for adjusting a seat assembly. The computer-program product includes instructions for operating an inflation device to inflate a first air bladder assembly oriented in a thoracic region of a seat back. The inflation device operates to inflate a second air bladder assembly oriented in at least one of a lumbar region, a sacrum region, and a scapular region of the seat back, after initiating inflation of the first air bladder assembly. In embodiments, the product provides for sequential posture alignment. 
         [0008]    According to at least another embodiment, a method for adjusting a seat assembly measures pressure values from a plurality of sensors in a plurality of zones of a seat assembly. The data is compared to determine if the occupant is seated evenly. An actuator is adjusted to balance the occupant posture seating position. 
         [0009]    According to at least another embodiment, a method for adjusting a seat assembly inflates a first air bladder assembly or a first series of multiple bladders oriented in a thoracic region of a seat back. A second air bladder assembly or a second series of multiple bladders is oriented in at least one of a lumbar region, a sacrum region, and a scapular region of the seat back, and is inflated after initiating inflation of the first air bladder assembly. In embodiments, the method provides for sequential posture alignment. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a flowchart of a method for determining various adjustment positions of a vehicle seat assembly for various users, according to an embodiment; 
           [0011]      FIG. 2  is a graph of data collected in the method of  FIG. 1 ; 
           [0012]      FIG. 3  is a front perspective view of a vehicle seat assembly, illustrated partially disassembled, according to an embodiment; 
           [0013]      FIG. 4  is a display image for a vehicle seating system according to an embodiment; 
           [0014]      FIG. 5  is another display image for the vehicle seating system of  FIG. 4 ; 
           [0015]      FIG. 6  is another display image for the vehicle seating system of  FIG. 4 ; 
           [0016]      FIG. 7  is another display image for the vehicle seating system of  FIG. 4 ; 
           [0017]      FIG. 8  is another display image for the vehicle seating system of  FIG. 4 ; 
           [0018]      FIG. 9  is another display image for the vehicle seating system of  FIG. 4 ; 
           [0019]      FIG. 10  is a flowchart of a method for adjusting a vehicle seat assembly according to an embodiment; 
           [0020]      FIG. 11  is a flowchart of another method for adjusting a vehicle seat assembly according to another embodiment; 
           [0021]      FIG. 12  is a rear schematic view of a seat assembly and a skeletal occupant according to an embodiment; 
           [0022]      FIG. 13  is a side schematic view of actuation zones and direction of a seat actuation system; and 
           [0023]      FIG. 14  is a series of side schematic views of an occupant in various postures. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. 
         [0025]    A comfort, posture and wellness seating system for vehicle seat assemblies provides a visual interface with adjustment hardware organically or inorganically. The system may be employed to properly configure any new or existing seating system. The system can also address specific comfort, posture or preferences, such as thoracic support. The seating system objectifies comfort data and biomechanical knowledge to make the data transferable. The seating system connects biomechanical optimization to measurable engineering data to make a complete comfort, posture and wellness seating system. 
         [0026]    The comfort, posture and wellness seating system integrates anthropometry, bio-mechanics, and historical seating comfort data. The seating system can be employed in original equipment for vehicles or in aftermarket products. Applicable markets include automotive, mass transit, airlines, etc., as well as non-vehicular seating such as office, home, commercial, and public venue seating. 
         [0027]    Referring now to  FIG. 1 , a flowchart of a method for determining various adjustment positions of a vehicle seat assembly for various users is illustrated, according to an embodiment. Data collection may occur at block  20 . The data collection  20  may include expert positioning of a suitable sample of occupants for optimal comfort or preferred posture by a medical professional. The data collection  20  can be used at specific sites on an ongoing basis if required. The expert input provides a high level of expert comfort, posture and personalized fitting. 
         [0028]    The data  22  may be based on anthropometry, body pressure distribution (BPD), status of actuators (such as pressure of inflatable air bladders, status of valves or the like), or other data that provides a comfort, posture and biomechanically optimized position of an adjustable vehicle seat assembly. The data is collected in a knowledge base  24  or table for setting adjustments based on categories of data. The knowledge base  24  may be compiled from the expert positioned data  20  and the occupant specific data  22 . The setting adjustments from the knowledge base  24  are utilized for pre-set options  26  in a vehicle seat assembly  28 . The setting adjustments  24  can be customized by a user at a controller or display  30 . 
         [0029]    Referring to  FIG. 2 , input data  20 ,  22  can be plotted versus adjustment settings  20 ,  24  for high level categorization. The settings  20 ,  24  can be categorized by topology clustering for setting the pre-set options  26 . Various setting options  26  may be provided for various types of driving. For example a touring setting may provide per package settings and basic comfort, posture and biomechanically optimized seating position recommendations. The touring setting may also provide optimal visibility, use of features and controls, and the like. A performance setting may be provided for active drivers to provide a more erect position with firmer seating. Additionally, a luxury setting may be more reclined with softer seating. 
         [0030]      FIG. 3  illustrates the vehicle seat assembly  28  with a cover removed. The seat assembly  28  includes a seat cushion  32  adapted to be mounted for motor-driven adjustable translation in a fore and aft direction and in an up and down direction of a vehicle. The seat assembly  28  includes a seat back  34  pivotally connected to the seat cushion  32  to extend generally upright relative to the seat cushion  32  for motor-driven pivotal adjustment relative to the seat cushion  32 . A head restraint (not shown) is mounted for motor-driven adjustable translation to the seat back  34 . 
         [0031]    At least one compressor  36  provides a source of air to the seat assembly  28 . A plurality of valves  38  receive the compressed air and are controlled by a controller  39  for regulating compressed air into and out of the seat assembly  28 . The seat cushion  32  includes a forward left air bladder  40 , a forward right air bladder  42 , a rear left air bladder  44 , a rear right air bladder  46 , a left side bolster air bladder  48 , and a right side bolster air bladder  50 . The seat back  34  includes a plurality of lumbar air bladders  52 , a plurality of thoracic air bladders  54 , a left side bolster air bladder  56 , and a right side bolster air bladder  58 . The valves  38  may be provided as a common valve bank that is housed in the seat back  34  or under the seat cushion  32 ; or the valves  38  may each be provided on each of the air bladders  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58 . The compressor  36  may be provided in the seat back  34 , the seat cushion  32  or concealed within the vehicle body. The controller  39  may be provided in a module under the seat cushion  32 , and may be a multifunction controller that also controls other functions in the vehicle. 
         [0032]    It is believed that supporting the thoracic region of the spine can reduce forces and support as much as one-third of the upper body mass. By increasing support of the upper body mass, loads are reduced on the muscles, ligaments, and spine and pelvic regions. Decreased load reduces fatigue on these areas of the body. The thoracic air bladders  54  are adjustable to provide the right degree of support in the correct location necessary to reduce such loading. 
         [0033]    The controller  39  receives the adjustment settings  24  from pre-set data  26  or from customized data  30 . The data may be input from an interface that is provided in the vehicle. The interface may be integrated into the vehicle, such as an instrument panel display that is in suitable wired or wireless communication with the controller  39 . The interface may be remote, such as a personal digital assistant (PDA) including phones, tablets and the like. The interface may be provided as a smart device application, wherein users enter relevant information about themselves. The smart phone interface may not require on-site expertise or seat properties. The remote interface permits a user to transport settings to each vehicle, such as personal passenger vehicles, airline seating, rental cars, and the like. 
         [0034]      FIGS. 4-9  illustrate display images from an interface, such as a tablet.  FIG. 4  illustrates a welcome screen wherein a data collection process is initiated.  FIG. 5  illustrates a screen wherein a user name is input to identify the user.  FIG. 6  illustrates another input screen wherein anthropometric and personal health data, such as wellness and activity level, is collected. This data is utilized to adjust the seat to the pre-set options  26 , based on prior-collected data  22  in knowledge base  24 . 
         [0035]    Each of the air bladders  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58  may include a pressure sensor to detect air pressure in the respective bladder  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58 . Any pressure sensor is contemplated, such as a pneumatic pressure sensor at the outlet valve of each respective air bladder  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58 . Pressure can also be sensed by contact pressure sensors disposed in front of or behind some or all of the respective air bladders, including on a front or rear surface thereof. The contact pressure sensors may include pressure-sensing mats, such as those available by Tekscan®, Inc. of 307 West First Street. South Boston, Mass. 02127-1309, USA.  FIG. 7  illustrates a depiction of the vehicle seat assembly  28  with zones ranging in color to depict a distribution of pressure upon the seat. This visualization may assist an occupant in positioning upon the seat assembly  28  with live visual feedback. 
         [0036]    A dynamic comfort, posture and biomechanically optimized option is offered. Selection of the dynamic comfort option measures the pressure in the sensors at  FIG. 8 , and displays a live view as in  FIG. 9 . The controller  39  compares the sensor values, and if the controller  39  determines that the occupant is not seated evenly, the controller  39  balances the air pressure in opposing air bladders to balance the occupant seating position. 
         [0037]      FIG. 10  depicts a flowchart for a method for adjusting the seat assembly  28  according to an embodiment. At block  60  the user comfort fit survey is completed. This process may be performed in an application on a PDA, tablet or smartphone, or in a controller in the vehicle. At block  62 , real time user data is sent to a gateway module, or controller  39 . In block  64 , the seat assembly  28  is positioned, and the air bladder values are adjusted. At block  66 , the gateway module receives an occupant weight distribution from the air bladder pressure sensors. At block  68  live values are adjusted, such as a percentage of bladder fullness. At block  70 , the values are sent to the interface application, and the range of values is assigned a range of colors. In block  72 , a live view is displayed, as in  FIG. 9 . Steps  66  and  68  are repeated for dynamically adjusting the seat assembly  28  to the occupant&#39;s position. Steps  66 ,  70  and  72  are repeated incrementally to provide the live view of the pressure distribution. 
         [0038]      FIG. 11  depicts a flowchart for a method for adjusting the seat assembly  28  according to another embodiment. At block  74  a welcome screen initiates a data collection process. At block  76  a user name is input to identify the user. At block  78  another input screen includes a questionnaire wherein anthropometric and ergonomic data and activity level is collected. This data is utilized to adjust the seat at block  80  to the pre-set options  26 , based on prior-collected data  22  in knowledge base  24 . At block  82 , a depiction of the vehicle seat assembly  28  is provided with zones ranging in color to depict a distribution of pressure upon the seat assembly  28 . If manual adjustment is selected at block  84 , the occupant can select a zone of the seat for adjustment, such as thoracic  86 , back bolster  88 , lumbar  90  and cushion bolster  92 . Once manual adjustment is completed, the live view body pressure distribution (BPD) screen  82  is updated. If a dynamic mode is selected at block  84 , then the adjustments and live view are updated based on the measurements from the pressure sensors and the anthropometric data. 
         [0039]    Misalignments of spinal vertebrae and discs may cause irritation to the nervous system and may be an underlying cause to many health problems. Additionally, spinal misalignments can be a contributing factor to a herniated disc, a bulging disc, a facet joint problem, osteoarthritis and spinal stenosis. Sequential adjustment of a seat assembly can enhance posture to minimize spinal misalignments. 
         [0040]      FIGS. 12 and 13  illustrate a seat assembly referenced by numeral  100 . The seat assembly  100  is similar to prior embodiments, and is illustrated schematically without the frame, cushioning, trim, controller, valves, compressor and the like. The seat assembly  100  is also illustrated with a skeletal occupant for discussion of mechanical orientations of relevant biomechanical features of average occupants. The seat assembly  100  is depicted by an arrangement of air bladder assemblies, each named for a targeted position within the seat assembly  100  with reference to a corresponding contact region of an occupant. The air bladder assemblies include a thoracic air bladder assembly  101  located in a thoracic region of the seat assembly  100  to support a thoracic region of an occupant, which is the T1 to T12 vertebrae, the ribs and in between the scapulae or shoulder blades. 
         [0041]    Referring to  FIG. 12 , a thoracic zone air bladder assembly  101  includes a scapular air bladder  102 , a medial thoracic air bladder  103  below the scapular air bladder  102 ; and a low thoracic air bladder  104  is also provided beneath the medial thoracic air bladder  103 , which extend to support spine, scapula, and ribs. The three thoracic air bladders  102 ,  103 ,  104  permit independent control of these regions for targeted support. 
         [0042]    With continued reference to  FIG. 12  a lumbar zone air bladder assembly  109  is provided below the thoracic air bladder assembly  101  to support the lower back at L1-L5 vertebrae. The lumbar zone air bladder assembly  109  includes a pair of air bladders  105 ,  106  according to an embodiment. 
         [0043]    With continued reference to  FIG. 12 , a sacral zone air bladder assembly  117  is provided below the lumbar air bladder assembly  109  to support the sacral regions of the occupant. The sacral zone air bladder assembly  117  may be provided with a single air bladder  107 . 
         [0044]    According to at least one embodiment, the air bladders  102 ,  103 ,  104 ,  105 ,  106 ,  107  are inflated in a sequence to support posture alignment, posture support and movement. The sequence can be controlled by the seat controller  39  as described above in prior embodiments. Initially, the thoracic air bladder assembly  101  is inflated. The thoracic air bladders  102 ,  103 ,  104  may be inflated individually or simultaneously.  FIG. 14  illustrates posture of an occupant during the inflation of the thoracic air bladders  103 ,  104  from left to right as the occupant approaches and achieves a wellness and posture position from back support  108  ( FIG. 13 ) and forward motion (arrow T,  FIG. 13 ) promoting pressure applied in thoracic T5-T10 vertebrae. With the improved posture, the occupant is induced to straighten its back and sit upright. 
         [0045]    Subsequently, the lumbar air bladders  105 ,  106  are inflated thereby supporting the lumbar vertebrae with pressure  110  in  FIG. 14 , while the lower thorax and lumbar vertebrae move rearward (arrow L/T), and the cervical vertebrae (arrow C) move rearward. Next, the scapular air bladder  102  is inflated for scapular support. Subsequently, the sacral air bladder  107  is inflated for sacrum pressure  112  ( FIG. 13 ) to promote a slight forward tilt. 
         [0046]    Referring again to  FIG. 12 , the seat assembly  100  may include a plurality of sensors each in at least one of the air bladders  102 ,  103 ,  104 ,  105 ,  106 ,  107 . The sensors measure pressure or proximity at each location to provide feedback to the controller  39  for subsequent adjustment and monitoring as described in the prior embodiments. The sensors may be bladder pressure sensors, bladder valve pressure feedback sensors, proximity sensors, tri-axial angular measurement sensors or the like. Additionally, any arrangement and quantity of sensors is contemplated for various seat assembly embodiments. 
         [0047]    While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.