Patent Publication Number: US-9428086-B2

Title: Over-travel mechanism for easy-entry system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation of U.S. patent application Ser. No. 14/332,908 filed Jul. 16, 2014, now U.S. Pat. No. 9,254,761, entitled OVER-TRAVEL MECHANISM FOR EASY-ENTRY SYSTEM, the entire disclosure of which is hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to a seat assembly having an easy-entry system, and more particularly, to a seat assembly having an over-travel mechanism for use in conjunction with the easy-entry system. 
     BACKGROUND OF THE INVENTION 
     In vehicles having a third row seating option, it is generally necessary to move one of the left or right rear seats to a forward leaning easy-entry position to allow greater access to the third row seating located behind the rear seat assemblies. In order to move a rear seat assembly to an easy-entry position, the seatback will generally be pivoted forward relative to a seat portion of the seat assembly, and the seat assembly will move forward along a track system. Generally, as the seatback is pivoted forward, a latch mechanism will unlock from the track system to allow the seat assembly to move forward along the seat track. A seat track lock release stroke generally requires a finite displacement in order to trigger the latch mechanism to unlock from the seat track. If the minimum stroke to unlock the latch mechanism is not achieved during an easy-entry function, then the seat track may be subject to a ratcheting noise resulting from the latch mechanism being partially engaged with the seat track. Further, if the minimum stroke is not achieved, the latch mechanism may be fully locked with the seat track, thereby resulting in the seat assembly being locked in position on the seat track. Thus, an over-travel mechanism is desired to ensure that the track mechanism is fully and consistently released from the seat track during an easy-entry function. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention includes a seat assembly with a seatback pivotally coupled to a seat member. The seatback is rotatable between use, release and over-travel positions relative to the seat member. A sector and a track release lever pivotally are coupled to the seat member and are configured to rotate with the seatback between the use, release and over-travel positions. A disengagement rod is flexibly coupled to the sector and the track release lever, such that rotation of the seatback to the release and over-travel positions causes the track release lever to unlock the seat assembly from a seat track. 
     Another aspect of the present invention includes a seat assembly having an easy-entry system. The easy-entry system includes a seat frame having a seatback pivotally coupled to a seat member. An external lever is operably coupled to an engagement lever disposed on the seat frame and is configured to activate the engagement lever to move the seatback into an engaged position with a sector pivotally coupled to the seat frame. A disengagement rod flexibly is coupled to a spring member disposed on the sector at a first end and further coupled to a track release lever at a second end. As such, rotation of the seatback to a release position rotates the track release lever to unlock the seat assembly from a seat track. Further rotation of the seatback from the release position to an over-travel position loads the spring member but does not further rotate the track release lever. 
     Yet another aspect of the present invention includes a seat assembly having a seat frame including a pivoting seatback and a seat member. A disengagement rod and a spring member are coupled between a sector and a track release lever, such that pivoting the seatback to a release position rotates the sector and the track release lever to unlock the seat assembly from a seat track. The seatback of the seat assembly is further moveable to an over-travel position wherein the spring member loads as the sector rotates. 
     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 side elevational view of a seat assembly in an upright locked use position, wherein the seat assembly includes an easy-entry system and over-travel mechanism; 
         FIG. 2  is a side perspective view of a disengagement rod and spring connection of the over-travel mechanism of  FIG. 1 ; 
         FIG. 3  is a side elevational view of the seat assembly of  FIG. 1  with the easy-entry system activated; 
         FIG. 4  is a side elevational view of the seat assembly of  FIG. 3  with the seatback being pivoted towards a forward leaning position and further showing a latch mechanism in a latched position; 
         FIG. 5  is a side elevational view of the seat assembly of  FIG. 4  showing relative movement of the seatback towards a forward leaning position and relative movement of a sector plate engaged with a crank pin, further showing relative movement of a latch mechanism being moved to an unlatched position; 
         FIG. 6  is a side elevational view of the seat assembly of  FIG. 5  showing the seatback and sector plate in a final over-travel position; 
         FIG. 7A  is a side elevational view of the over-travel mechanism showing relative displacement of the sector plate; and 
         FIG. 7B  is a side elevational view of the seat assembly of  FIG. 7A  showing relative movement of the seatback between free, engaged and over-travel positions. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED 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. 
     As used herein, the terms “easy-entry function” and “easy-entry system” refer to the ability of a seat assembly to move from an upright or partially reclined use position, as shown in  FIG. 1 , to an upright or forward leaning easy-entry position, as shown in  FIGS. 5 and 6 . The easy-entry system is the mechanism by which the easy-entry function is executed for providing increased access to an area disposed behind the seat assembly. The easy-entry function is most commonly used with a rear seat assembly for providing access to a third row seating option in a vehicle. 
       FIGS. 1-7B  generally depict a seat assembly having an easy-entry system disposed on a right side of the seat assembly. Thus, the seat assembly depicted in  FIGS. 1-7B  would generally be positioned behind a passenger seat in a vehicle as a rear seat assembly. A left hand side rear seat assembly will generally have an easy-entry system disposed on the left side of the seat assembly in a similar, but mirrored configuration relative to the seat assembly depicted in  FIGS. 1-7B . In this way, the left and right rear seats of the present invention include easy-entry systems which are readily accessible in an external position on the rear seats when the rear doors of the vehicle are opened. Thus, the seat assembly of the present invention is configured to have dual parallel seat tracks that are latched and unlatched using the easy-entry system on both left and right sides of the seat assembly. 
     Referring now to  FIG. 1 , the reference numeral  10  generally designates a seat assembly for use in a vehicle interior. The seat assembly  10  includes a seatback  12  which is pivotally coupled to a seat member  14  to define a seat frame  15 . The seat member  14  is contemplated to be slidably coupled to a vehicle floor along a seat track assembly  11  at mounts  11   a ,  11   b . In this way, the seat assembly  10  is moveable along the vehicle floor in forward and rearward directions along the path as indicated by arrow A. The seat assembly  10  is shown in  FIG. 1  as having side members  16 ,  18  which generally define the seatback  12  and the seat member  14  respectively. The seat assembly  10  of  FIG. 1  is shown having a seat cover and cushions removed to reveal side members  16 ,  18  as well as the easy-entry system  20  of the present invention. It is contemplated that the seat assembly  10 , in assembly, would include parallel side members relative to side members  16 ,  18  having any number of cross members disposed therebetween for providing structure to the seat assembly  10  for supporting a vehicle occupant. 
     As further shown in  FIG. 1 , the easy-entry system  20  includes a number of components disposed on first and second portions  18   a ,  18   b  of side member  18 . First portion  18   a  of side member  18  is generally a horizontal portion, while second portion  18   b  is generally an upright portion which is pivotally coupled to side member  16  of the seatback  12  at pivot point P 1 . The easy-entry system  20  allows for the seatback  12  to rotate forward along a path as indicated by arrow B to a forward leaning over-travel position as shown in  FIG. 6 . As shown in  FIG. 1 , the seatback  12  is in a locked position L which is a partially reclined use position U configured to receive a vehicle occupant. The easy-entry system  20  includes a sector  22  which is pivotally coupled to the second portion  18   b  of side member  18 . The sector  22  includes an engagement slot  24  for engaging a crank  26  when the easy-entry system  20  is activated. The crank  26  includes a pin  28  at a lower end thereof which engages the engagement slot  24  of the sector  22  when the easy-entry system  20  is activated. The crank  26  is pivotally coupled to a travel bracket  30  which is configured to move along a rounded upper portion  18   c  of side member  18  during an easy-entry function. The travel bracket  30  is coupled to the crank  26  at pivot point P 2  and is further coupled to the second portion  18   b  of side member  18  via a spring  32 . In operation, the spring  32  is used to bias the travel bracket  30  back to the in use position shown in  FIG. 1 . The easy-entry system  20  further includes an engagement lever  34  having a connection arm  36  which is coupled to a cable  52 . The engagement lever  34  is pivotally coupled to side member  18  at location  37  and includes a biasing spring  38  to bias the engagement lever  34  towards the at-rest position shown in  FIG. 1 . The engagement lever  34  is used to activate the easy-entry system  20  by engaging the crank  26  with the sector  22 . The activation of the easy-entry system  20  is executed by a user engaging an external lever  58  which is generally positioned on an external side of the seat assembly  10  and is accessible when the vehicle door is open. The external lever  58  is connected to cable  52  and is moveable along a path indicated by arrow F 1  between an at-rest position  60 , shown in  FIG. 1 , to an activated release position  62 , shown in  FIG. 3 . Moving the external lever  58  upward along path F 1  to the release position  62 , pulls the cable  52  in a direction as indicated by arrow F 2 . This action pivots the engagement lever  34  in a direction as indicated by arrow F 3 . The pivoting action of the engagement lever  34  moves the crank  26  along a path indicated by arrow F 4  into engagement with the sector  22 . Specifically, pin  28  of the crank  26  is caused to be engaged with engagement slot  24  of sector  22  by the movement of the connection arm  36 . As further shown in  FIG. 1 , the cable  52  is coupled to side member  18  at cable mount  54 . A cable housing  56  protects the cable  52  within the seat assembly  10  towards the connection of the cable  52  to the external lever  58 . Activation of the easy-entry system  20  is further described below with reference to  FIG. 3 . 
     The easy-entry system  20  further includes a track release lever  40  which is pivotally coupled to side member  18 . The track release lever  40  includes an upright arm  42  that is coupled to a disengagement rod  44 . The disengagement rod  44  is contemplated to be a rigid member which is further coupled to a spring member  46  mounted on a body portion  22   a  of the sector  22 . The spring member  46  includes a first leg  46   a  which is coupled to a first end  44   a  of the disengagement rod  44 . A second end  44   b  of the disengagement rod  44  is coupled to the upright arm  42  of the track release lever  40 . In use, the disengagement rod  44  travels in forward and rearward directions as indicated by arrow E. This movement which then pivots the upright arm  42  in a direction as indicated by arrow D, such that the track release lever  40  also pivots along a path as indicated by arrow C. The track release lever  40  is further coupled to a track latch piston  50  which is shown in  FIG. 1  in a latched position. While in the upright latched position, the track latch piston  50  locks the seat assembly  10  in its current position on the seat track  11 . As further described below, the track latch piston  50  can be vertically depressed to an unlatched position to allow the seat assembly  10  to move freely along the seat track  11  in forward and rearward directions as indicated by arrow A. 
     Referring now to  FIG. 2 , the disengagement rod  44  is shown as coupled to spring member  46 . Specifically, the disengagement rod  44  includes a first end  44   a  which is coupled to first leg  46   a  of the spring member  46  in a hook like manner. The spring member  46  further includes a second leg  46   b  which is coupled to a mounting bracket  22   b  disposed on the body portion  22   a  of the sector  22 . In the embodiment shown in  FIG. 2 , the spring member  46  is a clock spring having a wound coil body portion  46   c . The first end  44   a  of disengagement rod  44  is shown disposed at a slot  22   c  which is positioned through the body portion  22   a  of the sector  22 . The movement of the sector  22  during an easy-entry function is further described below. This movement of the sector  22  correlates to the movement of the disengagement rod  44  along the path indicated by arrow E as well as an interaction between the disengagement rod  44  and the sector  22  via spring member  46 . 
     Referring now to  FIG. 3 , the easy-entry system  20  is shown in an engaged or activated position. Thus, engagement lever  34  has pivoted in a car-forward direction as indicated by arrow F 3  towards the sector  22 . The movement of the engagement lever  34  is caused by the generally upward movement of external lever  58  along path F 1  to the release position  62  which pulls the cable  52  along path F 2 . The crank  26  has moved along the path F 4  such that the pin  28  is now engaged with engagement slot  24  of the sector  22  due to movement of the connection arm  36 . The travel bracket  30  is configured to move along the upper portion  18   c  of side member  18  in a direction as indicated by arrow G. Further, the seatback  12  is now in the unlocked position UL, which is an activated position due to the movement of the external lever  58  to the release position  62  and is thus ready for a forward incline movement along the path indicated by arrow B relative to seat member  14 . 
     Referring now to  FIGS. 4 and 5 , the seatback  12  has been rotated forward to the fully upright position UP, shown in  FIG. 4 , to a release position R shown in  FIG. 5 , along the path indicated by arrow B. The pin  28  of the crank  26  is engaged with the engagement slot  24  of the sector  22 . As shown in  FIG. 5 , the sector  22  rotates forward along a path as indicated by arrow H as driven by the rotation of the seatback  12 , such that a lower portion  22   d  of the sector  22  moves in a car-rearward direction from  FIG. 4  to  FIG. 5 . This movement causes the disengagement rod  44  to move in the car-rearward direction as indicated by arrow E. This car-rearward movement of the disengagement rod  44  provides for the rotational movement of the track release lever  40  which is coupled to pin  51  at slot  41  which is further coupled to the track latch piston  50 . As the track release lever  40  rotates in a rearward direction along the path indicated by arrow C shown in  FIG. 5 , the pin  51  is pushed downward within slot  41  such that the track latch piston  50  is depressed in a vertical direction as indicated by arrow I. In the depressed position, the track latch piston  50  has unlatched the seat assembly  10  from the seat track  11 , such that the seat assembly  10  is now ready for movement along the seat track  11  as indicated by arrow A. As shown in  FIG. 5 , the track release lever  40  has been rotated to a fully rotated unlocked position. 
     Referring now to  FIG. 6 , the seatback  12  is shown in an over-travel position OT. As used herein, the term “over-travel position” means that the seatback  12  has moved to a position beyond that which is required to release or unlock the seat assembly  10  from the seat track  11 . As shown in  FIG. 6 , the over-travel position OT may be a forward leaning position of the seatback  12  relative to the seat member  14 . This movement is often caused by a user trying to pull the seatback  12  in a car-forward direction to activate the easy-entry system  20 . However, moving the seatback  12  to the over-travel position OT can cause problems with the rotation of the track release lever  40  via the disengagement rod  44 . This is because, as mentioned above, the normal seat assembly requires a finite amount of movement in order to fully release the seat assembly from a seat track. This is most likely due to a static or fixed connection between a disengagement rod and a sector, which if over exerted upon, can fail in an easy-entry function. However, with the present invention, the easy-entry system  20  includes a kinetic or flexible connection between the disengagement rod  44  and the sector  22  at spring member  46  within slot  22   c  of the sector  22  as best shown in  FIG. 2 . The flexible connection of the disengagement rod  44  to the sector  22  in the present invention provides for a kinetic or forgiving coupling which allows for movement of the seatback  12  to the over-travel position OT without damaging the easy-entry system  20 . Rather, as the seatback  12  moves to the over-travel position OT, the spring member  46  absorbs an amount of the force realized on the disengagement rod  44  as the sector continues to rotate along the path as indicated by arrow H. In this way, the flexible connection of the disengagement rod  44  and sector  22  allows for some play as the seatback  12  moves to the over-travel position OT. As noted above with reference to  FIG. 5 , the track release lever  40  is already in the fully rotated unlocked position when the seatback  12  is in the release position R. As the seatback  12  rotates from the release position R of  FIG. 5  to the over-travel position OT of  FIG. 6 , the track release lever  40  does not rotate, even though the sector  22  continues to rotate with the seatback  12 . Thus, the movement of the seatback  12  from the release position R of  FIG. 5  to the over-travel position OT of  FIG. 6  does not affect the position of the track release lever  40 , thereby minimizing any damage to the seat track  11 , track latch piston  50  and track release lever  40  that could be caused by trying to over-rotate the track release lever  40 . The movement of the easy-entry system  20  is further described below with specific reference to  FIGS. 7A-7B . 
     Referring now to  FIGS. 7A-7B , the sector  22  is depicted showing relative movement of the sector  22  along path H in to sector positions SP 1 -SP 3 . Pin  28 , shown in  FIG. 1  as coupled to the crank  26 , is also shown in an activated or engaged pin position AC with slot  24  of sector  22 , and relative movement of the pin  28  is shown as pin positions PP 1 -PP 3  as the sector  22  moves along path H to sector positions SP 1 -SP 3 . Finally, the flexibly resilient coupling FC of the sector  22  and disengagement rod  44  at spring member  46  is shown, with relative movement of the flexible coupling FC shown in positions FC 1 -FC 3  as the sector  22  moves along path H to sector positions SP 1 -SP 3 . When the easy-entry system  20  is activated, as described above with reference to  FIG. 3 , the pin  28  moves into engagement with slot  24  of the sector  22  at activated position AC. As the seatback  12  moves forward along path B from the use position U to the upright position UP, the pin  28  moves to a notch  24   a  disposed in an upper end of engagement slot  24  in pin position PP 1 . This movement is due to the coupling of the seatback  12  and crank  26  described above. As the seatback  12  further moves along path B from the upright position UP to the release position R, the sector  22  rotates from sector position SP 1  to sector position SP 2  due to the sector&#39;s engagement with pin  28  as coupled to the crank  26  which moves with seatback  12  (shown and described above with reference to  FIG. 3 ) from pin position PP 1  to pin position PP 2 . With reference to the lower portion  22   d  of sector  22 , movement along path H from sector position SP 1  to sector position SP 2  causes movement of the flexible coupling FC of end  44   a  of disengagement rod  44  and spring member  46  to move from position FC 1  to FC 2 . This movement then pivots the upright arm  42  of track release lever  40  in a direction as indicated by arrow D, such that the pin  51  moves downward along path I to move the track latch piston  50  to the depressed release position, as described above with reference to  FIG. 5 . As shown in  FIG. 7A , the displacement of the flexible coupling FC from position FC 1  to FC 2  may be about 9 mm. This is enough displacement of the disengagement rod  44  to rotate the track release lever  40  to free the seat assembly  10  from the seat track  11  (shown in  FIG. 1 ). 
     As the seatback  12  further moves along path B from the release position R to the over-travel position OT, the sector  22  rotates from sector position SP 2  to sector position SP 3  due to the sector&#39;s engagement with pin  28 . Pin  28 , moving with the seatback  12 , moves from pin position PP 2  to pin position PP 3 . With reference to the lower portion  22   d  of sector  22 , movement along path H from sector position SP 2  to sector position SP 3  causes movement of the flexible coupling FC of end  44   a  of disengagement rod  44  and spring member  46  to move from position FC 2  to FC 3 . As noted above, in sector position SP 2 , the seat assembly  10  is released from the seat track  11  and free to move forward along path A (see  FIG. 5 ). Moving the seatback  12  to the over-travel position OT from the release position R will cause the spring member  46  to wind up or load as the track release lever  40  will have already reached its fully rotated unlocked position. In this way, the easy-entry system  20  allows the seatback  12  to move to the over-travel position OT from the release position R without damaging the connection of the disengagement rod  44  to the track release lever  40 . Without the flexible coupling FC of the disengagement rod  44  to the sector  22  at spring member  46 , the track release lever  40  could be damaged and cause the seat assembly  10  to partially or fully engage the seat track  11 , thereby prohibiting movement of the seat assembly  10  along the seat track  11 . It is contemplated the spring member  46  may have a minimum spring force or torque of about 2471 Nmm, or rather, a minimum torque necessary to overcome the track release force. It is further contemplated that a spring member could be disposed on the track release lever  40  at end  44   b  of the disengagement rod  44  to absorb rotation of the sector  22  when moving the seatback  12  to the over-travel position OT. 
     In the exemplary embodiment of  FIG. 7B , relative movement of the pin  28  from the activated position AC to pin position PP 1  is shown as being about a 16° rotation. As noted above, this movement of the pin  28  from the activated position AC to pin position PP 1  is executed by a user moving seatback  12  16° from the use position U to the upright position UP shown in  FIG. 7A . As further shown in  FIG. 7B , relative movement of the pin  28  from pin position PP 1  to pin position PP 2  is shown as being about an 11° rotation. Also noted above, this movement of the pin  28  from pin position PP 1  to pin position PP 2  is executed by a user moving seatback  12  from the upright position UP to the release position R shown in  FIG. 7A . This movement unlocks the seat assembly  10  from the seat track  11 . Finally, movement of the seatback  12  from the release position R to the over-travel position OT causes the pin  28  to move from pin position PP 2  to pin position PP 3  which is contemplated to be about a 4° rotation. One of ordinary skill in the art will appreciate that the degree of rotation may vary with different seat assemblies. 
     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 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 conditions, 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.