Abstract:
A cantilever supported headrest for use in a vehicle seat such as in the center occupant position in a non-first row application of a vehicle including a split seat back. The cantilever supported headrest includes a two-piece headrest support frame having a flange for connection to a square shaped tube end. The other end of the tube has a passage therein for receiving an anti-rotation bracket including an anti-rotation sleeve. A support bracket connecting the tube to a seat back frame includes a pair of aligned passages having the tube passing there through and the tube includes a plurality of notches for engagement with a height adjustment structure.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to the field of automotive seats and more particularly the present invention relates to a cantilevered headrest for use on an automotive seat such as a second or third row split bench seat.  
         BACKGROUND OF THE INVENTION  
         [0002]    Head restraints or headrests for automotive seats are well known as is the provision of head restraints for a rear seat of a vehicle such as in a second or third row seat. Typically, in a second row of a vehicle, there is a bench seat which may alternatively be split using some given proportion such as 50-50 or 60-40, for example. Since it is common to accommodate three passengers in a split bench seat, the provision of a headrest for the center occupant position is troublesome. There is difficulty due to the conflict between providing a headrest in a center occupant position versus the ability to fold down the split back rest without removing the center headrest.  
           [0003]    Additionally, in some countries, safety regulations will mandate a head restraint for all occupants in the vehicle, including the non-first row, center occupant and including split seats. Accordingly, there is a need to develop center position occupant headrests and, in particular, to develop headrests which will allow a split seat back to be folded without requiring the need to remove or alter the headrest.  
           [0004]    One known solution to the above problem is to provide the center occupant with a standard headrest capable of normal operation and support for the center occupant. This type of device uses two support posts for anchoring and supporting the headrest. However, the two support post solution is troublesome when considering that the seat back is split. A two post headrest support would likely require one support post positioned in one seat back and the other post positioned in the other seat back. In order to operate the split seat back and fold down one side, it is necessary to remove the headrest prior to folding down either of the split seat backs.  
           [0005]    It is also known to have a cantilevered head restraint wherein the head restraint is incorporated into a structural support member such as the seat back support member of a seat back frame of an integrated safety-belt seat (“ISS”, also known as all belts to seat or “ABTS”) support. Commonly, this solution is used in front row applications due the significant additional expense of such an ISS seat but may also be used in non-first row applications. However, as a practical matter, it is not feasible to have three ISS seats in a non-first row application since the middle position does not have a structural support member such as the seat back support member of a seat back frame. Today&#39;s vehicles are not designed to have a sufficient width to have three ISS seats in a non-first row application.  
           [0006]    Thus, there remains a significant need for a split seat back that can have headrests for each occupant of the seat including a center position occupant wherein the split seat back portions can be operated without the necessity of removing the center headrest. Further, there remains a need to provide an automotive split bench seat having adjustable headrests for each occupant of the seat including a center occupant and the split seat back portions can be operated without the necessity of removing a headrest.  
           [0007]    Even further, there remains a need to provide a split seat back having a non-rotating headrests for each occupant of the seat including a center occupant and the split seat back portions can be operated without the necessity of removing a headrest.  
         SUMMARY OF THE INVENTION  
         [0008]    A feature of the present is the provision of a cantilevered headrest for use in a center position of a non-first row, vehicle seating application having a split seat back.  
           [0009]    An additional feature of the present invention is the provision of a cantilevered headrest for use in a center position of vehicle seating application having a split seat back wherein the cantilevered headrest is height adjustable.  
           [0010]    An additional feature of the present invention is the provision of a cantilevered headrest for use in a center position of vehicle seating application having a split seat back wherein the cantilevered headrest is non-rotatable.  
           [0011]    One embodiment of the present invention relates to the provision of a cantilever supported headrest in a vehicle seat. The cantilever supported headrest is preferably provided for a middle occupant position for a non-first row vehicle seat application such as the middle occupant position in bench seat or the like having a 50-50 or 60-40 split bench seat having first and second seat back portions. The cantilever supported headrest is preferably provided on one of the first and second split seat backs and includes a tube having a height adjustment feature and a headrest member including a headrest support frame covered by a cushion and finish material.  
           [0012]    The headrest support frame preferably has a first side designed to face the seat occupant and a second side having a substantially rectangular shape designed to face away from the occupant. The headrest support frame preferably includes two portions welded together and a flange along a peripheral side edge of the second side of the headrest support frame.  
           [0013]    The tube is preferably shaped in a substantially rectangular shape to correspond with the rectangular shape of the second side of the headrest support frame so that the end of the tube is aligned with the flange and can be welded thereto.  
           [0014]    In one embodiment of the present invention, the tube further includes a passage at one end of the tube. The passage preferably consists of a pair of longitudinally extending slots aligned on opposite sides of the tube. In a further embodiment of the present invention, the cantilever supported headrest further includes a three sided support bracket having a pair of aligned passages for the tube to pass through and an anti-rotation bracket having a substantially u-shaped configuration having a leg section located in the passage in the tube to prevent the tube from rotating. An anti-rotation clip having a substantially u-shaped configuration including a pair of side members located on the middle section of the u-shaped anti-rotation bracket and located in the passage of the tube to eliminate buzz, squeaks and rattle problems between the interface of the tube and the anti-rotation bracket. The anti-rotation clip is preferably made of a polymeric material.  
           [0015]    It is desirable to provide an automotive seat that provides one or more of these or other advantageous features. Other features and advantages will be made apparent from the following description. The teachings disclosed extend to those embodiments that fall within the scope of the appended claims, regardless of whether they accomplish one or more of the aforementioned needs. BRIEF DESCRIPTION OF THE DRAWINGS  
           [0016]    [0016]FIG. 1 is a partial sectional, perspective view of a split bench vehicle seat including a cantilever supported headrest according to the present invention;  
           [0017]    [0017]FIG. 2 is a partial side view of the cantilever supported headrest of FIG. 1;  
           [0018]    [0018]FIG. 3 is a partial front view of the cantilever supported headrest of FIG. 1;  
           [0019]    [0019]FIG. 4 is a sectional view of the anti-rotation bracket of the cantilever supported headrest according to the present invention taken along the line  4 - 4  in FIG. 3;  
           [0020]    [0020]FIG. 5 is a partial rear view of the cantilever supported headrest according to the present invention showing the detail of the connection between the tube and a headrest support frame; and  
           [0021]    [0021]FIG. 6 is a partial perspective view of the of a headrest support frame according to the present invention showing the detail of the connection between the tube and the anti-rotation bracket and anti-rotation clip. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    Referring generally to FIGS. 1 through 6 there is shown a vehicle seat  10  in the form of a 50-50 split bench seat having a first seat  12  and a second seat  14 . The first seat  12  includes a first seat base  16  and a first seat back  18 . Similarly, the second seat  14  includes a second seat base  20  and a second seat back  22 . The first seat  12  preferably includes a headrest  24  and the second seat  14  preferably includes a headrest  26 . The headrests  24  and  26  are aligned with first and second occupant positions of the vehicle seat  10  and are preferably made using any known or appropriate headrest support design.  
         [0023]    The first and second seats  12  and  14 , respectively, are preferably made of any known or appropriate construction. By way of example only, with reference to the second seat back  22 , there is shown a seat back frame  28  having any known or appropriate construction. The seat back frame  28  is preferably covered by any known or appropriate type of a foam layer  30  and a finish material layer  32  as is known.  
         [0024]    A cantilever supported headrest  40  according to the present invention includes a headrest support member  42  and a support and adjustment member  44 . The support and adjustment member  44  connects the cantilever supported headrest  40  to the seat back frame  28 .  
         [0025]    The cantilever supported headrest  40  further includes a support bracket  46  connected to the seat back frame  28 , an anti-rotation bracket  48  and a tube  50 . The support bracket  46  is preferably positioned toward the top of the seat back frame  28  and has a substantially three-sided shape design and provides the tube  50  with substantial support against loads applied to the head support member  42 . The support bracket  46  is preferably formed from a high strength material such as steel and is preferably welded to the seat back frame  28 . However, it should be understood that any known or appropriate material may be used for the support bracket  46  and it is preferably made from the same material as the seat back frame  28 . The anti-rotation bracket  48  is preferably positioned below the support bracket  46  and is also preferably attached to the seat back frame  28  and is made of a similar material as the support bracket  46  and is also attached using any known or appropriate attachment or connection device, such as a weld, as long as it maintains the attachment of the support bracket  46  to the seat back frame  28  under the substantial load conditions that are common for head rest applications and which are increased due to the cantilever supported nature of the present design.  
         [0026]    The tube  50  is preferably made to have a designed construction. The tube  50  has a generally circular cross section and is made from a high strength steel and is finished appropriately using any known or suitable manufacturing and finishing techniques. The tube  50  has a first end  52  connected to the anti-rotation bracket  48  and a second end  54  located distal from the first end  52  for connection with the headrest support member  42 . The second end  54  is preferably shaped into a substantially rectangular shape to substantially correspond the headrest support member  42  to provide an appropriate connection.  
         [0027]    The end  54  of the tube  50  includes a first portion  56  extending horizontally and aligned with a top portion  58  of the headrest support member  42 . A second portion  60  of the tube  50  extends downward from the first portion  56  at an angle offset from vertical along a side portion  62  of the headrest support member  42 . The tube  50  then has a third portion  64  extending substantially parallel to the first portion  56  along a bottom portion  66  of the headrest support member  42  and terminating at an ultimate end point  68 .  
         [0028]    As best shown in FIG. 5, the headrest support member  42  includes a first half  70  and a second half  72  which are connected along a seam  74 . The seam  74  preferably has a scalloped, wavy or sinusoidal shape forming the connection between the first and second halves  70  and  72  to help in making certain the two halves are properly aligned. The first and second halves  70  and  72  are then preferably, permanently connected together by welding along the seam  74 .  
         [0029]    The bottom portion  66  of the headrest support member  42  further includes a first tab  76  extending in a direction toward the first portion  58  of the headrest support member  42  to capture the third portion  64  of the end  54  of the tube  50 . The first tab  76  preferably extends across the seam  74  such that the first tab  76  includes two portions.  
         [0030]    The headrest support member  42  further includes a second tab  78  as part of the bottom portion  66  aligned to abut with the ultimate end  68  of the tube  50 . The second tab  78  also extends in a direction toward the first portion  58  of the headrest support member  42  but the second tab  78  is preferably aligned substantially perpendicular with the first tab  76 . As the second tab  78  is taken form the bottom portion  66  of the first half  70  of the headrest support member  42 , it creates a hole  80  which extends from the second tab  78  toward a second side portion  82  arranged opposite the side portion  62 . The hole  80  is further defined by an end  84  located toward the bottom portion  66  of the second side portion  82  of the first half  70  of the headrest support member  42 . The headrest support member  42  further includes a plurality of holes  86  designed to lighten the weight of the headrest support member  42  while still providing substantial support to a seat occupant.  
         [0031]    Further, it has been found that it is particularly advantageous to have the tube  50  designed such that it&#39;s thickness is not substantially less than 0.13 times the diameter for a high strength low alloy steel or any comparable material having a minimum yield strength of approximately at least 345 MPa. Alternatively, it is stated that the tube  50  has a diameter to thickness ratio of approximately greater than or equal to 7.62. Further, if the tube  50  is of the variety having a seam or weld (such as an electronically welded seam), the seam is preferably located opposite the plurality of adjustment notches  90 .  
         [0032]    The support and adjustment member  44  also includes an adjustment mechanism  88  as is well known for adjusting the height of a headrest such as the cantilever supported headrest  40 . The adjustment mechanism  88  preferably interacts with a plurality of notches or holes  90  aligned longitudinally on the tube  50 . The adjustment mechanism  88  is connected to the support bracket  46  and preferably passes through a passage in the support bracket  46 , the passage including a first hole  92  located on a first side  94  and a second hole  96  located in a second side  98 . The support bracket  46  further includes a third side  100  extending between the first and second sides  94  and  98 , respectively, such that the support bracket  46  forms a substantially three-sided figure having the adjustment mechanism  88  passing there through and the tube  50  also passes through the first and second holes  92  and  96 , respectively. The support bracket  46  is preferably connected to the adjustment mechanism  88  and the tube  50  at a point between the first end  52  and the second end  54  of the tube  50 .  
         [0033]    The support and adjustment member  44  further includes the anti-rotation bracket  48 . The anti-rotation bracket  48  is connected or combined with the tube  50 . The tube  50  includes a includes a passage  102  extending longitudinally along a given length of the first end  52  of the tube  50 . The passage  102  preferably extends upward from the first end  52  to allow the anti-rotation bracket  48  to be inserted into the passage  102 . The passage  102  includes a first slot  104  aligned toward one side of the tube  50  and a second slot  106  preferably aligned opposite the first slot  104  such that the first and second slot  104  and  106 , respectively, are preferably aligned along a diagonal of the tube  50 .  
         [0034]    The anti-rotation bracket  48  has a substantially u-shaped configuration designed for connection with the seat back frame  28 . The u-shaped portion of the anti-rotation bracket  48  includes a first leg  108  having a first length, a second leg  110  having a second length and a middle portion  112  interconnecting the first leg  108  and the second leg  110 . The anti-rotation bracket  48  further preferably includes a first attachment portion  114  extending from the first leg  108  and a second attachment portion  116  extending from the second leg  110 . The first and second extension portions  114  and  116 , respectively, preferably extend in directions substantially perpendicular to the first and second legs  108  and  110 , respectively and are aligned with respective portions of the back frame  28  so the so the first and second extension portions  114  and  116 , respectively, may be welded with the back frame  28 . In one preferred embodiment the first leg  108  is longer than the second leg  110  to allow the anti-rotation bracket  48  to be connected to a stepped portion of the back frame  28 .  
         [0035]    The anti-rotation bracket  48  further preferably includes a first rib  118  extending between the first leg  108  and the first extension portion  114  to reinforce the anti-rotation bracket to help it carry more loads applied through the tube  50 . Similarly, the anti-rotation bracket  48  further preferably includes a second rib  120  extending between the second leg  110  and the second extension portion  116  to further reinforce the anti-rotation bracket to help it carry more loads applied through the tube  50 . In view of and consistent with the description above, the anti-rotation bracket  48  is preferably made as a unitary piece using a stamping forming technique. Alternatively, the anti-rotation bracket  48  may be made using other known forming techniques without departing from the broader aspects of the present invention.  
         [0036]    The cantilever headrest  40  of the present invention further includes an anti-rotation sleeve or clip  122  having a substantially u-shaped configuration including a first leg  124  and a second leg  126 . The first leg  124  and second leg  126  are connected together through a middle portion  128 . The anti-rotation sleeve  122  is connected to the first leg  108  of the anti-rotation bracket  48  and is located in the passage  102  of the tube  50 . The anti-rotation sleeve  122  is preferably made from a nylon material or similar plastic material to provide an appropriate level of compliance between the anti-rotation bracket  48  and the tube  50  while preventing any squeaks and rattles that would result from having the metal of the anti-rotation bracket  48  interact directly with the metal of the tube  50 .  
         [0037]    The anti-rotation bracket  48  further preferably includes a tab  130  (not shown) for interaction with a notch  132  located in the center of the middle portion  128 . The notch  132  locates the anti-rotation sleeve  122  on the anti-rotation bracket  48  and prevents the anti-rotation sleeve  122  from moving on the anti-rotation bracket  48 .  
         [0038]    While the drawings and examples describe herein include various exemplary embodiments, they only serve the purpose of illustrating one preferred embodiment the invention. The inventions disclosed are not limited to the specific forms shown. The systems and methods depicted and described are not limited to the precise details and conditions disclosed. Furthermore, other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangements of the exemplary embodiments without departing from the scope of the invention as expressed in the appended claims.