Patent Publication Number: US-9902293-B2

Title: Independent cushion extension with optimized leg-splay angle

Description:
CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM OF PRIORITY 
     This application is a continuation-in-part of and claims priority under 35 U.S.C. §120 to commonly assigned, and related U.S. patent application Ser. No. 13/748,862, now U.S. Pat. No. 9,399,418, filed Jan. 24, 2013, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to a vehicle seating assembly, and more particularly to a vehicle seating assembly that includes independent cushion extension with an optimized leg-splay angle. 
     BACKGROUND OF THE INVENTION 
     Modern vehicle seats are becoming more and more comfortable as designers develop a greater understanding of human ergonomics, posture, and comfortability. Vehicle seating assemblies that include comfort components in the vehicle seat back and the vehicle seat can provide the driver and passengers with improved comfort and increased endurance for extensive vehicle rides. Additionally, various sizes and shapes of drivers and passengers can prove challenging when providing vehicle seating assemblies. Accordingly, vehicle seating assemblies that include components optimized to accommodate the different sizes and shapes of drivers and passengers, as well as the desired posture and sitting positions of those drivers and passengers, has become increasingly important. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the present invention, a vehicle seating assembly includes a vehicle seating assembly including a seat frame having a longitudinal centerline and a seat H-point along the centerline. A first extendable member is disposed on a forward portion of the seat frame along a first side of the centerline and is operable between extended and retracted positions. A second extendable member adjacent to and independent of the first extendable member is disposed on the forward portion of the seat frame along a second, opposite side of centerline and is operable between extended and retracted positions. The first and the second extendable members extend forwardly from the seat H-point at a lateral angle of between 5 to 10 degrees relative the centerline, respectively. 
     According to another aspect of the present invention, a vehicle seating assembly includes a vehicle seating assembly comprising a seat frame having a longitudinal centerline and a seat H-point along the centerline. A first leg support is pivotally coupled with a forward portion of the seat frame, the first leg support including a first extendable member extending forwardly from the seat H-point along a first side of the centerline at a lateral angle of between 5 to 10 degrees relative the centerline. A second leg support is independent of the first leg support and is pivotally coupled with the forward portion of the seat frame. The second leg support includes a second extendable member extending forwardly from the seat H-point along a second opposite side of the centerline at a lateral angle of between 5 to 10 degrees relative the centerline. 
     According to yet another aspect of the present invention, a vehicle seating assembly includes a vehicle seating assembly comprising a seat frame having a longitudinal centerline and a seat H-point along the centerline. First and second adjacent and independently extendable members extend forwardly from the seat H-point at a lateral angle of between 5 to 10 degrees relative to and on opposing sides of the centerline. 
     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 
       In the drawings: 
         FIG. 1  is a top perspective view of one embodiment of a vehicle seating assembly of the present invention disposed in a vehicle; 
         FIG. 2  is a top perspective view of the vehicle seating assembly of  FIG. 1 ; 
         FIG. 3  is a side elevational view of a vehicle seating assembly of the present invention; 
         FIG. 4  is a top plan view of the vehicle seating assembly of  FIG. 3 ; 
         FIG. 5  is a top perspective exploded view of the seat of the vehicle seating assembly of  FIG. 3 ; 
         FIG. 6  is a top perspective exploded view of a portion of the seat of the vehicle seating assembly of  FIG. 3 ; 
         FIG. 7  is a bottom perspective exploded view of a portion of the seat of the vehicle seating assembly of  FIG. 3 ; 
         FIG. 8  is a top perspective view of the vehicle seating assembly of  FIG. 3  with first and second leg supports in the retracted and lowered positions; 
         FIG. 8A  is a top perspective view of the leg supports of  FIG. 8 ; 
         FIG. 9  is a partial side cross-sectional elevational view taken at line IX-IX illustrating the leg supports of  FIG. 8  in a retracted position; 
         FIG. 10  is a top perspective view of the vehicle seating assembly of the present invention with one of the leg supports in a lowered position; 
         FIG. 10A  is a top perspective view of the leg supports of  FIG. 10  with one of the leg supports in a lowered position; 
         FIG. 11  is a partial side elevational cross-sectional view taken at line XI-XI of  FIG. 10A  illustrating one of the leg supports in an extended position; 
         FIG. 12  is a top perspective view of one embodiment of the vehicle seating assembly of the present invention with one of the leg supports in a raised position; 
         FIG. 12A  is a top perspective view of the leg supports of  FIG. 12  with one of the leg supports in the raised position; 
         FIG. 13A  is a partial side elevational cross-sectional view taken at XIIIA-XIIIA of the leg support of  FIG. 12A  in the raised position; 
         FIG. 13B  is a partial side elevational cross-sectional view of the leg support of  FIG. 13A  after movement from the raised position to the lowered position; and 
         FIG. 13C  is a partial side elevational cross-sectional view of the leg support of  FIG. 13B  after movement to the raised position and the retracted position. 
     
    
    
     DETAILED DESCRIPTION OF THE 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 to  FIGS. 1 and 2 , reference numeral  10  generally designates a vehicle seating assembly having a seat frame  12 . A first leg support  14  is pivotally coupled with a forward portion  16  of the seat frame  12 . The first leg support  14  is operable between raised and lowered positions. A first extendable member  20  is disposed on the first leg support  14  and is operable between extended and retracted positions. A second leg support  22  is adjacent to and independent of the first leg support  14  and is pivotally coupled with the forward portion  16  of the seat frame  12 . The second leg support  22  is operable between raised and lowered positions. A second extendable member  24  is disposed on the second leg support  22  and is operable between extended and retracted positions. 
     Referring again to  FIGS. 1 and 2 , the vehicle seating assembly  10  generally includes a seat  30  and a seat back  32  that supports a headrest  34  thereon. The seat back  32  is pivotally coupled with the seat  30 , such that the seat back  32  can be moved between upright and inclined positions. The headrest  34  is operably coupled with the seat back  32  and also positioned in a variety of positions relative to the seat back  32  to support the head and neck of a driver or a passenger. The seat frame  12  includes first and second side members  40 ,  42  ( FIG. 4 ) supported on legs  44  ( FIG. 5 ). Laterally extending frame members  43  ( FIG. 5 ) extend between the first and second side members  40 ,  42 . The legs  44  are operably coupled with seat track slide assemblies  46  that are secured to a floor  45  of a vehicle  49 . 
     Referring now to  FIGS. 3 and 4 , the vehicle seating assembly  10  is generally configured to apply selective support to the underside of the legs of the driver or passenger. Specifically, as shown in  FIG. 3 , each leg of the driver or passenger can be independently supported by the first and second leg supports  14 ,  22 . The first and second leg supports  14 ,  22  are moveable between raised and lowered positions, as well as between extended and retracted positions to modify an effective seating area  48  of the seat  30  and optimize accommodation of the size, shape, posture, and sitting positions of the driver or passenger. 
     As further shown in  FIG. 4 , a longitudinal centerline, designated as C, of the seat frame  12  functionally defines a split between the first extendable member  20  and the second extendable member  24 . The first extendable member  20  and the second extendable member  24  each extend forwardly from the seat H-point, designated as H, at a lateral angle α relative the centerline C. The first extendable member  20  and the second extendable member  24  preferably extend forward at an angle α laterally from the centerline C and forwardly from the H-point to provide better leg support and comfort on the outside of the occupant&#39;s thighs in a position that naturally conforms to the natural leg-splay of a human occupant. This leg-splay angle is maintained in both the stowed and deployed position for optimized comfort in all use position. The inventors of the present disclosure have determined that the angle α should be between 5 and 10 degrees, and preferably about 5 degrees, from the seat H-point along the centerline C of the seat frame  12 . The split between the first extendable member  20  and the second extendable member  24  at such an angle α has been unexpectedly found to provide improved comfort that reduces muscle strain and improves leg and thigh support. Thus, an extendable leg support  14 ,  22 , where the splayed angle α is precisely set at about 5 to 10 degrees (optimally at about 5 degrees) laterally from the centerline C and forward of the H-point of the seat frame  12  on each side of the centerline C, provides better leg support and comfort. 
     Referring now to  FIG. 5 , the vehicle seating assembly  10  includes a seat base  50  that is supported over the seat frame  12 . An interface member  52  is positioned between the seat frame  12  and the seat base  50 . The seat base  50  is disposed behind the first and second leg supports  14 ,  22 , and in front of the seat back  32 . The interface member  52  includes a pivot rod  54  that extends between first and second sides  56 ,  58  of the interface member  52 . Additionally, a rear portion of the interface member  52  includes a frame engagement component  59  that secures the interface member  52  to the seat frame  12 . The pivot rod  54  also includes first and second support bases  60 ,  62  that support the first and second leg supports  14 ,  22 , respectively. The first and second support bases  60 ,  62  are operably coupled with first and second motors  64 ,  66 . The first motor  64  is operably coupled with a slide  70  and a drive shaft  72 . The drive shaft  72  is capable of laterally translating a support body  74  between extended and retracted positions. The first support base  60  is configured to rotate the first leg support  14  about the pivot rod  54  between the raised and lowered positions, as discussed in further detail herein. Similarly, the second motor  66  is operably coupled with a slide  80  and a drive shaft  82 . The drive shaft  82  is capable of laterally translating a support body  84  of the second leg support  22  between extended and retracted positions. The second support base  62  is configured to rotate the second leg support  22  between the raised and lowered positions. 
     Referring again to  FIG. 5 , the interface member  52  includes a suspension frame  90  disposed thereon. The suspension frame  90  is configured to provide sufficient support to a suspension member  92  and a seat cushion  94 . Accordingly, the suspension frame  90  includes a shape that largely complements the shape of the seat cushion  94 . Specifically, the suspension frame  90  includes a body  96  defining an aperture  98  configured to receive the suspension member  92 , which supports the seat cushion  94 . At the same time, first and second wings  100 ,  102  extend from the body  96  and are configured to support first and second side cushions  104 ,  106  of the seat cushion  94 . The seat cushion  94  is supported above the suspension frame  90  and is protected by a coverstock  110 . It is anticipated that the coverstock  110  could be any of a variety of materials, including traditional fabrics, as well as leathers, vinyls, etc. A lateral seat brace  112  is positioned below the first and second leg supports  14 ,  22  and is coupled to the seat frame  12 . The lateral seat brace  112  assists in guiding the first and second leg supports  14 ,  22  between the various positions, and, at the same time, provides additional rigidity to the seat frame  12  of the vehicle seating assembly  10 . The lateral seat brace  112  also includes a shroud that protects a forward portion  16  of the vehicle seating assembly  10  and is aesthetically pleasing to view. 
     Referring now to  FIGS. 6 and 7 , the first and second leg supports  14 ,  22  will be discussed in further detail. The first and second leg supports  14 ,  22  are configured to engage the interface member  52  of the vehicle seating assembly  10 . Specifically, the first and second support bases  60 ,  62  are pivotally coupled with the pivot rod  54  that is rotatably or fixedly coupled with the interface member  52  of the vehicle seating assembly  10 . The first and second support bases  60 ,  62  are operable between the raised and lowered positions about the pivot rod  54 . The first and second motors  64 ,  66  of the first and second leg supports  14 ,  22 , respectively, are positioned on the first and second support bases  60 ,  62 . The first and second motors  64 ,  66  are operably coupled with the drive shafts  72 ,  82 , respectively. Each drive shaft  72 ,  82  includes a screw gear  120  ( FIG. 9 ) disposed thereon. The screw gear  120  allows for linear translation of the first and second leg supports  14 ,  22  between the extended and retracted positions, as discussed below. 
     Referring again to  FIGS. 6 and 7 , each of the first and second leg supports  14 ,  22  includes a slide assembly  122 . The support bodies  74 ,  84  are configured to engage the slide assembly  122 . The support bodies  74 ,  84  of the first and second leg supports  14 ,  22  include a receiving slot  124  configured to receive a portion of the slide assembly  122 . Each receiving slot  124  includes an enlarged recess  126  that is configured to receive a slide block  130  on the slide assembly  122 . The slide block  130  is linearly translatable via the screw gear  120  between fore and aft positions. The slide block  130  is configured to engage the enlarged recess  126 , thereby coupling the support body  74  or  84  with the slide assembly  122 . As described in further detail below, when the slide block  130  is in the aft position, the relevant leg support  14  or  22  is in the retracted position. Similarly, when the slide block  130  is in the fore position, the relevant leg support  14  or  22  is in the extended position. 
     Referring again to  FIGS. 6 and 7 , each support body  74 ,  84  is generally configured to be coupled with a flex member  140  disposed thereon. The flex member  140  includes an open matrix  142  of flex apertures  144  that provide additional comfort and flexibility for the driver or passenger. At the same time, the flex apertures  144  provide some breathability in the first and second leg supports  14 ,  22  of the vehicle seating assembly  10 . The flex member  140  is positioned on top of the support body  74  or  84  and is covered by a protective wrap  146 . The protective wrap  146  is covered by a leg support coverstock  148  and a cushion layer  150 . The leg support coverstock  148  and the cushion layer  150  protect the protective wrap  146  and the flex member  140 . As shown in  FIG. 7 , each support body  74 ,  84  includes a number of engagement pins  154  that secure the flex member  140  to the support bodies  74 ,  84 . Each of the first and second support bases  60 ,  62  of the first and second leg supports  14 ,  22 , respectively, includes a rearwardly extending flange  160  that extends on an opposite side from a body  162  of the first and second support bases  60 ,  62 . The rearwardly extending flange  160  is coupled with tension springs  164  that are coupled to a mounting bracket  166 . The tension springs  164  bias the relevant support base  60  or  62  to the raised position. It is generally contemplated that the support body  74  of the first leg support  14  and the support body  84  of the second leg support  22  may be moveable to the raised position and the lowered position via an actuation assembly operably coupled with a motor. Alternatively, adjustment of the first and second leg supports  14 ,  22  may be made manually via a gear system, as understood by one having ordinary skill in the art. 
     Referring now to  FIGS. 8 and 8A , the vehicle seating assembly  10  is illustrated with the first and second leg supports  14 ,  22  moved to an initial position. In the initial position, the first and second leg supports  14 ,  22  are in the retracted position and also in the lowered position. In this initial position, the seating area  48  of the seat  30  has not been enlarged. Accordingly, the seating area  48  is generally configured to support a driver or passenger that is smaller in stature. In the event the driver or passenger has a larger stature and wishes to change the effective seating area  48  of the vehicle seating assembly  10 , then the first and second leg supports  14 ,  22  can be raised independently and also extended independently, preferably at an optimized lateral angle α of between 5 to 10 degrees relative the centerline C. 
     Referring now to  FIGS. 10 and 10A , in the illustrated embodiment, the second leg support  22  has been translated to the extended position. To move the second leg support  22  to the extended position, the driver or passenger would simply engage a toggle switch on the seat  30  that is operably coupled to the second motor  66 . The second motor  66  then activates, which turns the drive shaft  82  that is coupled with the screw gear  120 . As the screw gear  120  rotates, the support body  84  of the second leg support  22  is pushed outwardly away from the seat base  50 . At the same time, the first leg support  14  maintains position and does not move. In the event the driver or passenger also wanted the first leg support  14  to be moved to the extended position, the driver or passenger could engage in the same behavior to actuate the first motor  64 , which would then force the support body  74  of the first leg support  14  outward in a similar fashion to that described above with reference to the second leg support  22 . 
     As shown in  FIG. 11 , as the screw gear  120  rotates, the slide block  130  begins to move relative to the screw gear  120 . Specifically, when the second motor  66  operates in a first direction, the screw gear  120  rotates such that threads of the screw gear  120  push internal threads of the slide block  130 , which translates the slide block  130  and the second leg support  22  away from the seat base  50  (corresponding to the extended position of the second leg support  22 ). When the second motor  66  operates in a second direction, the screw gear  120  turns in a second direction opposite the first direction, such that the slide block  130  is drawn toward the seat base  50  (corresponding with the retracted position of the second leg support  22 ). 
     Referring now to  FIGS. 12 and 12A , the vehicle seating assembly  10  is illustrated with the second leg support  22  in a raised position. In the raised position, the second leg support  22  is better situated to hold or support the underside of a leg of the driver or passenger when the leg is not extended. The second leg support  22  is moved to the raised position under the force of the tension springs  164  alone, or under the force of the tension springs  164  and a motor operably coupled to the second support base  62  that urges the second leg support  22  to the raised position. The first leg support  14  operates in much the same way. Notably, the first and second leg supports  14 ,  22  may be at the lowered position, the raised position, or any position therebetween simultaneously. However, the first and second leg supports  14 ,  22  may also be placed at different positions. For example, the first leg support  14  may be at the lowered position, while the second leg support  22  may be at the raised position, as shown in  FIG. 12A . Moreover, at the same time, regardless of the raised or lowered positions of the first and second leg supports  14 ,  22 , the first and second leg supports  14 ,  22  may also be at the extended or retracted positions. Again, the first and second leg supports  14 ,  22  may be placed at the retracted position or the extended position simultaneously. Alternatively, the first and second leg supports  14 ,  22  may be positioned differently. For example, the first leg support  14  may be at the lowered position and the retracted position, while the second leg support  22  may be at the extended position and the raised position. 
     As shown in the illustrated embodiment of  FIGS. 13A and 13B , the second support base  62  of the second leg support  22  upon which the second motor  66  is positioned is rotated upwardly (clockwise). As generally noted above, movement of the second leg support  22  by way of the second support base  62  can occur by the force of the tension springs  164  coupling the rearwardly extending flange  160  to the mounting bracket  166  in the seat  30 , by a motor  66  that is operably coupled with the second support base  62  to rotate the second support base  62  between the raised and lowered positions, or can be by way of a motor  66  that is supplemented by the tension springs  164  that extend between the rearwardly extending flange  160  and the mounting bracket  166 . As shown in  FIG. 13C , it will be understood that the first and second leg supports  14 ,  22  can be in the raised or lowered position, or any position therebetween, and at the same time, be in the extended or retracted position.  FIG. 13C  illustrates the second leg support  22  in the raised position and the retracted position. Movement of the first and second leg supports  14 ,  22  between the raised and lowered positions is independent of movement of the first and second leg supports  14 ,  22  between the extended and retracted positions. 
     The vehicle seating assembly as disclosed herein includes first and second independently moveable leg supports configured to provide independent support to the legs of a driver or passenger. For example, for a driver, frequently, the right leg of the driver is in an extended position to actuate the pedals. At the same time, particularly in vehicles equipped with an automatic transmission that does not require the manipulation of a clutch pedal, the left leg of the driver may be retracted to provide comfort to the driver. The vehicle seating assembly  10  as disclosed herein can allow for additional support under the right leg of the driver, thereby minimizing the likelihood that the endurance of the driver will wane over long trips. The vehicle seating  10  assembly as disclosed herein also provides additional comfort as the leg supports can be specifically moved and adjusted to conform to the preferred seating style of a particular driver or passenger. 
     It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that, unless otherwise described, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating positions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods 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.