Abstract:
A vehicle seat and reclining mechanism are disclosed that provide for adjusting the angle of inclination of a seat back relative to a seat base and also permits easy entry to the area behind the seat by allowing the seat back to be released to move between an adjusted angle of inclination and a position in which the seat back is folded over the seat base. The reclining mechanism may include three or four release mechanisms that are all coaxially attached to the vehicle seat to permit the seat back to pivot about a single axis.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to DE 10 2011 004 090.0, filed Feb. 14, 2011, the disclosure of which is hereby incorporated by reference in its entirety. 
     TECHNICAL FIELD 
     The present invention relates to seat back reclining mechanisms that cooperate with an easy entry seat release mechanism. 
     BACKGROUND 
     Seat reclining mechanisms and easy entry seat release mechanisms are known and examples of prior art patents disclosing such devices include but are not limited to U.S. Pat. Nos. 5,611,599; 5,755,491; 5,536,217; 4,930,841; 4,668,013; 4,634,181; and 4,629,251. 
     SUMMARY 
     A recliner apparatus is provided for a vehicle seat that includes a seat base and a seat back that may be adjusted to change the angle of inclination of the seat back and that may also be released to permit easy entry to seats or storage areas located behind the vehicle seat. In one embodiment of the recliner apparatus, a shaft having a first end portion extends outboard of a first side of the seat base and a second end portion extends outboard of a second side of the seat base. The shaft pivots about a pivot axis. First and second recliners connect the seat back to the first and second end portions of the shaft and are adjustable about the pivot axis to selectively hold the seat back at a selected angle within a range of tilt angles. A third recliner connects the first recliner to the seat back and is attached coaxially to the first recliner to pivot the seat back about the pivot axis between a forwardly folded position and the selected angle. 
     Other features and aspects of the recliner apparatus may include providing first and second recliners that are disengaged while being adjusted to the selected angle. Further, the third recliner may be operatively connected to the second recliner so that the second and third recliners may be disengaged to pivot the seat back between the forwardly folded position and the selected angle. The first and second recliners may be disengaged by actuating a first manual actuator to adjust the seat back to the selected angle. The second and third recliners may be disengaged by actuating a second manual actuator to pivot the seat back between the forwardly folded position and the selected angle. The first and second recliners may be disengaged by pivoting the shaft to disengage each of the first and second recliners by rotating a cam that disengages a plurality of locking elements from a gear ring provided in each of the first and second recliners. 
     Another embodiment of recliner apparatus described above may include a fourth recliner that connects the second recliner to the seat back and is adjustable about the pivot axis. The fourth recliner is provided to pivot the seat back between a forwardly folded position and the selected angle. In the embodiment of the recliner apparatus having a fourth recliner, the first and second recliners may be continuously engaged while being adjusted to the selected angle. For example, the continuously engaged recliners may each have an eccentric gear set in which an inner gear is rotated by the shaft to drive a gear ring that is continuously engaged by the inner gear. The third recliner and fourth recliners are disengaged as the seat back is pivoted between the forwardly folded and the selected angle. 
     Continuous type recliners and discontinuous recliners that are adjustable in small increments may be referred to a “comfort recliners” that are used to set the angle of inclination of the seat back to a comfortable position for the seat occupant. Discontinuous recliners are used as the “easy entry recliners” that are released to move the seat back between the folded forward position and the selected or comfort position. Discontinuous recliners used for comfort adjustment or easy entry are generally similar in structure with the easy entry type having end stops that permit a wide range of motion, for example, about 90 degrees. The specific range may of course be more or less than 90 degrees depending upon the design of the seat and the range of motion that is necessary to move the seat from the upright comfort position to the folded forward position. 
     There are a wide variety of recliner mechanisms of both the continuous and discontinuous type. Even though two specific designs of the two types of recliners are specifically disclosed, the invention should not be interpreted as being limited to any specific type of recliner. Continuous recliners are continuously engaged and current designs do not lend themselves to releasing for rapid travel which is preferred for easy entry mechanisms. Discontinuous recliners of conventional design may be used for comfort adjustment according to the invention. Conventional discontinuous recliners can be adapted to provide easy entry with memory by changing the end stop locations or modifying the control plate elements. 
     One or two easy entry discontinuous recliners may be combined with two discontinuous recliners to provide both comfort and easy entry functions. Two easy entry discontinuous recliners and two continuous recliners may be combined with two discontinuous recliners to provide both comfort and easy entry functions. 
     According to another aspect of the disclosure twin continuous and discontinuous recliners may be provided on opposite sides of a vehicle seat. The twin recliner apparatus may include a shaft having a first end portion that extends outboard of a first side of the seat base and a second end portion that extends outboard of a second side of the seat base. The shaft is mounted in the seat to pivot about a pivot axis. A first continuous recliner connects the seat back to the first end portion of the shaft and is adjustable about the pivot axis to selectively hold the seat back at a selected angle within a range of tilt angles. A second continuous recliner connects the seat back to the second end portion of the shaft and is adjustable about the pivot axis to selectively hold the seat back at the selected angle. A first discontinuous recliner connects the first continuous recliner to the seat back and is attached coaxially to the first continuous recliner. The first discontinuous recliner is provided to pivot the seat back about the pivot axis between a forwardly folded position and the selected angle. A second discontinuous recliner connects the second continuous recliner to the seat back and is attached coaxially to the second continuous recliner. The second discontinuous recliner is provided to pivot the seat back about the pivot axis between a forwardly folded position and the selected angle. 
     According to one aspect of the invention in which a fourth recliner is provided, the shaft may be is connected to a motor that rotates the shaft to adjust the first and second recliners to the selected angle. Alternatively, the shaft may be connected to a rotatable knob that rotates the shaft to adjust the first and second recliners to the selected angle. 
     In the three recliner embodiment, the recliner apparatus may also include a first weld plate that is attached to one recliner and a second weld plate that is attached to another recliner that are welded together. 
     In the four recliner embodiment, a first weld plate may be attached to one recliner and a second weld plate may be attached to another recliner. The weld plates are welded together to connect the two recliners. Further, the two recliners on the other side of the seat may be welded together in the same manner. 
     The invention may also be characterized as a vehicle seat that includes a seat back that is pivotally connected to a seat base to pivot about an axis with two continuous and two discontinuous recliner mechanisms. The first continuous recliner connects the seat back to the seat base and is adjustable about the pivot axis to selectively hold the seat back at a selected angle within a range of tilt angles. The second continuous recliner connects the seat back to the seat base and is adjustable about the pivot axis to selectively hold the seat back at the selected angle. The first discontinuous recliner connects the first continuous recliner to the seat back and is attached coaxially to the first continuous recliner. The first discontinuous recliner is provided to pivot the seat back about the pivot axis between a forwardly folded position and the selected angle. The second discontinuous recliner connects the second continuous recliner to the seat back and is attached coaxially to the second continuous recliner. The second discontinuous recliner is provided to pivot the seat back about the pivot axis between the forwardly folded position and the selected angle. 
     Another alternative aspect of the vehicle seat embodiment relates to providing a first weld plate that is attached to the first continuous recliner and a second weld plate that is attached to the first discontinuous recliner that are welded together to connect the first continuous recliner to the first discontinuous recliner. A third weld plate is attached to the second continuous recliner and a fourth weld plate is attached to the second discontinuous recliner that are welded together to connect the second continuous recliner to the second discontinuous recliner. The weld plates allow twin recliners to be provided on opposite sides of the seat that permit comfort tilt adjustment of the seat back and also easy entry with memory as to the previously adjusted seat back position. 
     These and other aspects of the present invention will be better understood in view of the attached drawings and the following detailed description of the illustrated embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle seat that is provided with a coaxial comfort and easy entry recliner assembly; 
         FIG. 2  is a front elevation view of a continuous/easy entry recliner assembly made according to one embodiment of the present invention; 
         FIG. 3  is a fragmentary front elevation view of a vehicle seat that is provided with a continuous/easy entry recliner assembly that is attached to opposite sides of a seat base that optionally may be provided with a motor according to one embodiment of the present invention; 
         FIG. 4  is a fragmentary front elevation view of a vehicle seat that is provided with a discontinuous/easy entry recliner assembly on one side of the vehicle seat and a slave discontinuous comfort recliner on the opposite side of the vehicle seat. 
         FIGS. 5A-B  are an exploded perspective view of a continuous recliner and a discontinuous easy entry recliner that are attached by a pair of weld plates to form a continuous/easy entry recliner assembly; and 
         FIG. 6  is a side elevation view of a weld plate that may be used with another weld plate to connect two recliner assemblies together to form a twin recliner assembly according to one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     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. 
     Referring to  FIG. 1 , a vehicle seat  10  is illustrated that includes a seat base  12  and a seat back  14 . A twin recliner assembly  16  is used to adjust the angular orientation of the seat back  14  relative to the seat base  12  in a comfort adjustment mode. The twin recliner assembly  16  also permits the seat back  14  to be folded flat over the seat base  12  in an easy entry with memory mode of operation. An adjustment handle  18  is provided on the twin recliner assembly  16  to permit manual adjustment of the twin recliner assembly  16  in some embodiments. An easy entry release handle  20  is provided on the seat back  14  that is used to actuate the easy entry portion of the twin recliner assembly  16 . 
     Referring to  FIG. 2 , a continuous/easy entry assembly  22  is illustrated that includes a continuous recliner  24  that is attached to a discontinuous/easy entry recliner  26 . Many different types of continuous recliners and discontinuous recliners are available that may be adapted to provide the dual mode of operation wherein both a comfort adjustment and easy entry adjustment may be provided by a twin recliner assembly and Applicants&#39; invention should not be limited to one particular type of recliner mechanism or another. 
     The continuous recliner  24  is provided with a first weld plate  30  that is welded to a second weld plate  32  that is connected to the discontinuous/easy entry recliner  26 . The continuous/easy entry assembly  22  is attached to an end portion of a shaft  34  that extends transversely across the seat base  12  as shown in  FIG. 3 . 
     Referring to  FIG. 3 , a seat base  12  and seat back  14  are shown with a pair of continuous/easy entry assemblies  22  on a first side  38  and a second side  40  of the seat base  12 . The continuous/easy entry assemblies  22  on each side include a continuous recliner  24  that is connected to a discontinuous recliner  26  by the first and second weld plates  30  and  32 . The shaft  34  connects the assemblies  22  through the seat base  12 . In the comfort adjustment mode, the motor  42  or the manual knob, may be used to turn the continuous recliner  24  on one side of the seat with the rotation of the shaft  34  communicating the rotation to the other side. A lever  44  is operatively connected to the discontinuous/easy entry recliner mechanisms  26  that are provided inboard of the continuous recliners  24  on both sides of the seat base  12 . The levers  44  are operated by control cables  46  that extend to the easy entry release handle  20  (shown in  FIG. 1 ). The easy entry release handle  20  is actuated to shift the control cables  46  and pivot the levers  44  to release the discontinuous easy entry recliner  26 . 
     Referring to  FIG. 4 , another alternative embodiment is illustrated that includes a discontinuous/easy entry assembly  48  on the second side  40  of the seat base  12  and a discontinuous comfort recliner  50  on the first side  30  of the seat base  12 . The discontinuous/easy entry assembly  48  controls the discontinuous comfort recliner  50  in one embodiment by transmitting rotational movements through the shaft  34  when the seat back  14  is adjusted in the comfort mode. When it is desired to provide the easy entry function, a first easy entry control cable  52  is actuated by actuating the easy entry release handle  20  shown in  FIG. 1 . When the first easy entry control cable  52  is shifted, a slave control cable  54  releases or engages the discontinuous comfort recliner  50 . A lever  56  is provided on the discontinuous/easy entry assembly  48  and on the discontinuous comfort recliner  50  that is operated by the control cables  52 ,  54 . 
     While the embodiment of  FIG. 4  is shown with a discontinuous/easy entry assembly  48  on one side, it is also possible to provide two discontinuous/easy entry assemblies  48  on opposite sides of the seat base  12 . If so, both may be operated by means of a first easy entry control cable and a second easy entry control cable  58  that may be used to actuate the recliner assemblies in the easy entry mode. 
     Referring to  FIGS. 5A and 5B , a continuous/easy entry assembly  22 , as previously described with reference to  FIGS. 2 and 3 , is shown in the exploded perspective view. The portion of the assembly  22  shown in  FIG. 5A  includes the discontinuous easy entry recliner  26  while the portion of the assembly  22  shown in  FIG. 5B  includes the continuous recliner  24 . It should be understood that the discontinuous recliner shown in  FIG. 5A  and continuous recliner shown in  FIG. 5B  are intended as mere examples of recliner mechanisms that may be used in accordance with the present invention. The description of the continuous/easy entry assembly  22  is provided to facilitate implementation of Applicants&#39; invention. It should be understood that the discontinuous/easy entry assembly described with reference to  FIG. 4  would include a discontinuous easy entry recliner  26  and a discontinuous comfort recliner  50  as described with reference to  FIG. 4 . 
     Referring to  FIG. 5A , a hub  60  is illustrated that is adapted to be connected to the shaft  34  shown in  FIG. 3 . A guide plate  62  is assembled to a gear plate  64  and held together by means of a case ring  66  on the outer periphery of the plates  62 ,  64 . The hub  60  extends through the guide plate  62  and gear plate  64 . A spacer  68  is provided between the case ring  66  and the gear plate  64  for the purpose of noise reduction. A cam  70  is secured to the hub  60  and is used to extend and retract a plurality of pawls  72  that are driven into engagement with, and released from, the gear plate  64  by rotating the hub  60  and cam  70  with the shaft  34 . 
     Each of the pawls  72  includes a protrusion  74  that adapted to be received in corresponding slots  78  formed in a control plate  80 . The control plate  80  is used to hold the pawls  72  out of engagement with the gear plate  64  until the seat back  14  is adjusted to the desired angular orientation relative to the seat base  12 . The same general arrangement may be used to provide an easy entry mode of operation by providing a plurality of elongated slots  82  in the control plate  80 . The elongated slots  82  are shown in phantom lines in  FIG. 5A . By elongating the slots, a range of free rotation of the seat back  14  may be extended to provide free travel between the adjusted position and a fold flat position of the seat back  14 . Range of motion may be approximately 90 degrees free travel and two latching positions may be established corresponding to the two positions of the seat back. When the seat back is returned to the upright position, the discontinuous comfort recliner  50  remains in the same position and thereby provides a “memory” of the previous comfort adjustment position. In other embodiments of the discontinuous recliner, end stops may be provided inside the guide plate  62  and gear plate  64  to provide range of motion stops instead of the slot in the control plate. 
     A plurality of springs  84  are mounted to the guide plate  62  to bias the cam  70  to engage the pawls  72  causing them to engage the gear plate  64 . The pawls  72  are received in channels  86  formed by guides  88  that are integrally formed in the guide plate  62 . 
     The weld plate  32  is also illustrated in  FIG. 5A  that is adapted to be secured to the gear plate  64 . The weld plate  32  may be welded or otherwise secured to the gear plate  64  and is provided to facilitate connecting the discontinuous easy entry recliner  26  to the continuous recliner  24  illustrated in  FIG. 5B . 
     Referring to  FIG. 5B , the continuous recliner  24  is shown to include an inner gear plate  90  that is received by an outer gear plate  92  in a continuously meshing relationship. A driver  94  is received within the inner gear plate  90  and the outer gear plate  92 . A cover  96  is retained by the driver to provide a lubricant seal and exclude contamination from the inner and outer gear plates  90  and  92 . A case ring  98  holds the inner and outer gear plates  90 ,  92  together in a relatively rotatable relationship. A spacer  100  is provided between the case ring  98  and the outer gear ring  92 . A retainer clip  102  is secured to the hub  94  to retain the hub within the gear plates  90  and  92 . A bearing ring  106  is retained in the outer gear plate  92 . A pair of wedges  108  is inserted inside the bearing ring  106  and are urged apart by means of a spring  110 . The wedges  108  provide an eccentric connection between the inner and outer gear plates  90  and  92  so that as the inner gear plate  90  is rotated, the outer gear plate  92  rotates incrementally. 
     Referring to  FIG. 6 , a weld plate  30  is illustrated and is used to secure a comfort adjustment recliner to an easy entry recliner. The continuous or discontinuous recliners may be used individually to provide comfort adjustment on conventional vehicle seats. The weld plate  30  that may be attached to another weld plate  32  to join two recliners together in a coaxial relationship this is aligned with the central axis of the shaft  34 . The weld plate  30  includes openings  18  that are adapted to receive posts  116  as shown in  FIG. 5B  that are normally used to secure the recliner to the seat frame (not shown). The posts  116  shown in  FIG. 5  are received in the openings  118  so that the weld plate  30  may be welded to the outer gear plate  92 . Similarly, a weld plate  32  as shown in  FIG. 5B  may be welded to the gear plate  64  with two protrusions  120  being received in two openings  122 . The protrusions  120  are formed in the exterior surface of the gear plate  64  and the openings  122  are provided in the weld plate  32  to align the parts. The weld plates  30  and  32  are then welded together by conventional welding techniques to weld a first set of flanges  124  on the first weld plate to a second set of weld flanges  126  that are provided on the second weld plate  32 . 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and 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.