Abstract:
A seat having a trim carrier. A flexible region includes a base portion integrally connected with the trim carrier and a distal portion. A connector includes a first end connected to the distal portion and a second end connected to a motor. Actuation of the motor draws the connector and consequently the distal portion downward toward the base portion, thereby arcing the flexible region.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to an integrated lumbar for a thin seat, and more particularly relates to an integrated lumbar system that manipulates a portion of a trim carrier. 
     BACKGROUND OF THE PRESENT INVENTION 
     Lumbar systems are frequently used in a variety of seating constructions. Lumbar support provides comfort and ideal ergonomic conditions to the lower back of a user, thereby creating a pleasant experience with the seating arrangement in which the lumbar system is incorporated. In the automobile industry, lumbar systems assist a user in maximum comfort during both long and short trips and assist in minimizing back pain that can sometimes be affiliated with lack of support to the lower back of a user. 
     SUMMARY OF THE PRESENT INVENTION 
     One aspect of the present invention includes a lumbar mechanism for a seat having a trim carrier. A flexible region includes a base portion integrally connected with the trim carrier and a distal portion. A connector includes a first end connected to the distal portion and a second end connected to a motor. Actuation of the motor draws the connector and consequently the distal portion downward toward the base portion, thereby arcing the flexible region. 
     Another aspect of the present invention includes a seating apparatus having a seat. A seat back is operably connected to the seat and includes a back frame. A trim carrier is adjacent the back frame. A cushion is adjacent the trim carrier. A coverstock is applied over the cushion. A flexible region is disposed within the trim carrier and operable between a deployed position and a non-deployed position. 
     Yet another aspect of the present invention includes a vehicle seat having a seat base. A seat back is operably coupled to the seat base and includes a seat frame and a trim carrier. The trim carrier includes a flexible lumbar region. A motor is adjacent the trim carrier and is operably connected to the lumbar region by a connector. 
     These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of one embodiment of a seat in which an integrated lumbar system is incorporated; 
         FIG. 2  is a top perspective view of one embodiment of a trim carrier having a flexible region; 
         FIG. 3  is a front elevational view of the trim carrier of  FIG. 2 ; 
         FIG. 4  is a side elevational view of a seat incorporating one embodiment of an integrated lumbar system of the present invention in a non-deployed position; 
         FIG. 4A  is a side elevational partial cross-sectional view of the seat back of  FIG. 4 ; 
         FIG. 5  is a side elevational view of the seat back of  FIG. 4  with the integrated lumbar system in a deployed position; 
         FIG. 5A  is a side elevational partial cross-sectional view of the seat back of  FIG. 5 ; 
         FIG. 6  is a side elevational view of a seat incorporating another embodiment of an integrated lumbar system of the present invention in a non-deployed position; 
         FIG. 6A  is a side elevational partial cross-sectional view of the seat back of  FIG. 6 ; 
         FIG. 7  is a side elevational view of the seat back of  FIG. 6  with the integrated lumbar system in a deployed position; and 
         FIG. 7A  is a side elevational partial cross-sectional view of the seat back of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Referring now to  FIGS. 1 and 2 , the reference numeral  10  generally designates a seating apparatus having a seat  12  and a seat back  14 . The seat back  14  is operably connected to the seat  12  and includes a back frame  16 . A trim carrier  18  is adjacent the back frame  16  and a cushion  20  ( FIG. 4A ) is adjacent the trim carrier  18 . A coverstock  22  ( FIG. 4A ) is applied over the cushion  20 . A flexible portion  24  is disposed within the trim carrier  18  and operable between a non-deployed position  26  ( FIG. 4 ) and a deployed position  28  ( FIG. 5 ). 
     The trim carrier  18  is specifically designed to provide comfort to the back of a seated user and may be used in any seat of a vehicle  29 . The trim carrier  18 , cushion  20 , and coverstock  22  act as a unit that conforms to the body shape of a seated user. When a user sits on the seat  12  and rests against the seat back  14 , the seat back  14  flexes to accommodate the weight and shape of the user, as outlined in further detail below. It is generally contemplated that the trim carrier  18  will be injection molded and made from a flexible polymer or fiberglass. 
     Referring again to  FIGS. 1 and 2 , the trim carrier  18  includes first and second side portions  30 ,  32  integrally formed with a top portion  34 . The first and second side portions  30 ,  32  wrap around the back frame  16 , which extends behind the trim carrier  18 . The trim carrier  18  also includes a mid-portion  36  substantially separated from the first and second side portions  30 ,  32  by first and second vertical elongate slots  40 ,  42 . The mid-portion  36  is flexible and includes a central cavity  37  in which the flexible portion  24  is disposed. The vertical elongate slots  40 ,  42  have a plurality of flex apertures  44  that deform when the back of a user applies pressure to the trim carrier  18 . The vertical elongate slots  40 ,  42  include an elongate web  46  that extends through the flex apertures  44  to provide some rigidity and structural integrity to the flex apertures  44 . When pressure is applied to the first side portion  30  or the second side portion  32 , the first side portion  30  or the second side  32  rotates slightly relative to the mid-portion  36 , thereby providing a flexible surface that, together with the cushion  20  and coverstock  22 , engages and comforts the back of a user. 
     Referring again to  FIG. 2 , the first and second vertical elongate slots  40 ,  42  are connected by a horizontal elongate slot  50  that also includes a plurality of flex apertures  52 . An elongate web  54  extends through the flex apertures  52 . In the illustrated embodiment, there are two horizontal rows of flex apertures  52  that allow for increased bending of the trim carrier  18  at the horizontal elongate slot  50  about a horizontal axis. It is contemplated that more or less rows of flex apertures  52  may be applied, depending on the desired flexibility of the trim carrier  18  at the horizontal elongate slot  50 . The horizontal elongate slot  50  allows slight flexure of the top portion  34  of the trim carrier  18  relative to the mid-portion  36  of the trim carrier  18 . Specifically, the horizontal elongate slot  50  allows the top portion  34  to deflect slightly forward or rearward relative to the mid-portion  36 , thereby providing additional comfort to the back of a user. Engagement slots  56  are positioned on a bottom portion  58  of the trim carrier  18  and are adapted to allow proper interface of the seat  12  to the seat back  14 . 
     Referring now to  FIGS. 3 and 4 , the mid-portion  36  of the trim carrier  18  includes an integrated lumbar device  60 . The integrated lumbar device  60  has the flexible portion  24  integrally connected with the mid-portion  36  of the trim carrier  18 . It is contemplated that the flex portion  24  may be connected to the mid-portion  36  of the trim carrier  18  on a top side  64 , first side  66 , second side  68 , or bottom side  70  of the flex portion  24 . However, it is also possible for the flex portion  24  to be connected on a single side of the flex portion  24 . 
     In the illustrated embodiment shown in  FIGS. 2-4 , the flex portion  24  is integrally connected with the mid-portion  36  at the bottom side  70  of the flex portion  24  at first and second connectors  72 ,  74 . The first and second connectors  72 ,  74  form a flexible living hinge  75  that allows for movement of the flex portion  24 , as will be described in further detail below. The connectors are separated by a base aperture  76 . A plurality of vertically-aligned apertures  78  are disposed above the base aperture  76 , and effectively lighten the weight of the trim carrier  18 , while at the same time provide additional flexibility to the flex portion  24 . Slots  80  are disposed on the first and second sides  66 ,  68  of the flex portion  24  that allow for bending of the flex portion  24  about a horizontal axis, as outlined in further detail below. The flex portion  24  and trim carrier  18  are constructed from a strong lightweight and resilient material that is flexible, but which will return to its original position after flexing. 
     Referring to  FIGS. 4 and 4A , the top side  64  of the flex portion  24  includes a rearwardly extending arm  83  having a guide aperture  82  adapted to receive a guide member  84 . The guide member  84  is disposed behind the trim carrier  18 . The guide member  84  extends from the mid-portion  36  down to the bottom of the trim carrier  18 . The guide aperture  82  is slidably engaged with the guide member  84 , such that the guide aperture  82  and the top side  64  of the flex portion  24  may be moved upward and downward between the deployed position  28  and the non-deployed position  26 , respectively. As shown in  FIGS. 3 and 3A , when the flex portion  24  is in the non-deployed position  26 , a side profile of the trim carrier  18  and the flex portion  24  maintain relatively consistent linear alignment. Consequently, the cushion  20  and the coverstock  22  also maintain substantially consistent linear alignment. 
     Referring now to  FIGS. 4-5A , a cable  90  is attached to the top side  64  of the flex portion  24  and also operably connected with an actuation device  88  in the form of a reel  93  of a motor system  92 . When the motor system  92  is activated, the reel  93 , connected with the motor system  92 , rotates counterclockwise, which causes the cable  90  to draw inward and rotate around the reel  93 . Consequently, the amount of cable  90  between the top side  64  of the flex portion  24  and the motor system  92  lessens, which causes the top side  64  of the flex portion  24  to draw downward. As the top side  64  of the flex portion  24  draws downward, the guide aperture  82  at the top side  64  of the flex portion  24  is guided downward by the guide member  84 , such that the flex portion  24  begins to bow outwardly and hinge at the living hinge  75 , as shown in  FIGS. 5 and 5A . The living hinge  75  is constructed from the same material as the trim carrier  18 , and it is contemplated that the living hinge  75  can be hinged for the entire life of the vehicle seat  12  and life of the vehicle without needing to be replaced. Additional flexibility is provided by the slots  80  in the flex portion  24 . As the flex portion  24  bows outwardly, the cushion  20  and the coverstock  22  also bow outwardly, thus providing added support to the lower back of a user. 
     Referring again to  FIGS. 4-5A , a toggle switch  94  that is operably connected with the motor system  92  can stop the motor system  92  at any position between the fully deployed position  28  and fully non-deployed position  26  to maximize comfort. The motor system  92  is positioned above a lower frame member  96  disposed inside the seat back  14 , and thus extra room below the seat  12  is not necessary. In the event the user wishes to lessen the lumbar support, then the toggle switch  94  is reversed, which consequently causes the motor system  92  to rotate the reel  93  in a clockwise direction, thus unreeling the cable  90  that was drawn in during the counterclockwise operation of the motor system  92 . The flex portion  24  is biased to the non-deployed position  26  and will eventually reestablish linear alignment with the trim carrier  18 . 
     Referring now to  FIGS. 6-7A , yet another embodiment of the present invention includes the actuation device  88  having a lever system  100  having a lever  102  that is operably connected with the cable  90 , and consequently the flex portion  24 . In operation, when the lever  102  of the lever system  100  is in a raised position  104  ( FIGS. 6 and 6A ), the cable  90  is in an unloaded condition, such that the flex portion  24 , as well as the cushion  20  and coverstock  22 , maintain a substantially linear orientation. When the lever  102  of the lever system  100  is rotated downward to a lowered position  106  ( FIGS. 7 and 7A ), the cable  90  is wound, at least partially, about the reel  93 , which shortens the amount of exposed cable  90 . Consequently, the top side  64  of the flex portion  24  is drawn downward. At the same time, the flex portion  24  bulges outwardly, thereby pushing the cushion  20  and coverstock  22  outwardly into a back supporting condition. The lever  102  of the lever system  100  is operably connected with a friction disc  108  that effectively holds the lever  102  in any of a plurality of positions. Consequently, the flex portion  24  may be set at any of a variety of lower back supporting conditions that allows for comfort to the back of different users of varying sizes and shapes. It is contemplated that a variety of other mechanisms could be incorporated into the lever system  100  to hold the lever  102  in a variety of fixed positions as would be understood by one having ordinary skill in the art. Both the lever system  100 , as well as the motor system  92 , are disposed into the seat back  14 . As a result, the need for additional space around or below the seating apparatus  10  that would otherwise be needed by activating devices of this kind is minimized. 
     The present invention provides a lumbar device that is comfortable to a user and that minimizes the overall thickness of a seat back  14 . In addition, the actuating device, which may include the motor system  92  or the lever system  100 , among other possible options, is incorporated in the seat back  14 , thus eliminating additional space above or below the seat  12  that would otherwise be needed to accommodate the actuating mechanism. Furthermore, the inclusion of a flex region as an integral part of the trim carrier  18  allows for ease of manufacture and installation of the trim carrier  18  into the seat back  14 . As a result, a lightweight seat  12  and seat back  14  are provided that are comfortable and designed for extended use over a long period of time. 
     It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.