Patent Publication Number: US-2017361748-A1

Title: Assembly For Adjusting A Lumbar Region Of A Seat

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates, generally, to vehicle seats and, more specifically, to an assembly for adjusting a lumbar region of a seat. 
     2. Description of the Related Art 
     Conventional seats known in the art include a base and a back configured to accommodate, support, and secure an occupant of a vehicle. The base is operatively attached to the vehicle, such as to a passenger compartment floorboard, and may be adapted to selectively move along the floorboard so as to effect selective legroom adjustment to accommodate differently-sized occupants. The back is pivotally attached to the base such that the occupant can selectively adjust the angular position of the back with respect to the base. 
     In addition to legroom adjustment and back/base angular position adjustment, seats known in the related art employ various mechanisms to facilitate adjustable support to the occupant at specific seat locations corresponding to anatomical regions of the body. By way of non-limiting example, the seat may include one or mechanisms to facilitate adjustment of lumbar support against the occupant&#39;s back, and/or bolster support against the occupant&#39;s hips, waist, or shoulders. Such selective adjustment is particularly advantageous when the occupant has been seated for an extended period of time. 
     There are a number of different types of mechanisms known in the related art for providing selectively adjustable support within a seat, including both manually-adjusted and power-adjusted mechanisms. 
     While seats and adjustment mechanisms known in the prior art have generally performed well for their intended purpose, there remains a need in the art for a seat adjustment mechanism assembly which strikes a substantial balance between packaging size, component cost, manufacturability, functionality, usability, and ergonomics. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the disadvantages in the related art in an assembly for adjusting a lumbar region of a seat having a back frame. The assembly includes a seat support adapted for suspension in the back frame of the seat. The seat support is movable between a first lumbar position and a second lumbar position. An actuator is operatively attached to the seat support to concurrently move with the seat support between the lumbar positions. The actuator includes a chassis and a drive mechanism. A wire extends between first and second longitudinal ends. The first end of the wire operatively engages the drive mechanism of the actuator, and the second end of the wire is adapted for attachment to the back frame of the seat. A conduit is disposed about at least a portion of the wire and has first and second ends. The first end of the conduit is coupled to the actuator. A first guide is mounted to the seat support with a portion of the wire adjacent the second end of the wire being slideably supported by the first guide. A second guide is mounted to the seat support spaced from the first guide with a portion of the wire being slideably supported by the second guide. An intermediate mounting device is provided having a mount adapted for attachment to the back frame of the seat. A portion of the wire is supported by the intermediate mounting device. The second end of the conduit is mounted to the intermediate mounting device such that movement of the drive mechanism moves the wire relative to the guides and the intermediate mounting device to facilitate movement of the first guide relative to the second end of the wire and movement of the second guide relative to the intermediate mounting device. 
     In this way, the adjustment mechanism of the present invention provides improved functionality and usability in connection with automotive seating systems and, at the same time, reduces the cost and complexity of manufacturing and assembling seating systems with improved improved features, such as increased comfort, adjustability, and ergonomics. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. 
         FIG. 1  is a perspective view of a vehicle seat having a back frame in which an assembly according to one embodiment of the present invention is suspended for adjusting a lumbar region of the seat. 
         FIG. 2  is a perspective view of the back frame and the assembly of  FIG. 1  showing a seat support, an actuator, a wire, a conduit, a first guide, a second guide, and an intermediate mounting device. 
         FIG. 2A  is an enlarged view of the back frame and assembly of  FIG. 2 , showing additional detail of the conduit, wire, intermediate mounting device, and the second guide. 
         FIG. 2B  is an another enlarged view of the back frame and assembly of  FIG. 2 , showing additional detail of the wire and the first guide. 
         FIG. 3  is a rotated perspective view of the assembly of  FIG. 2 . 
         FIG. 4  is a side view of the assembly of  FIG. 3 . 
         FIG. 5  is a rotated perspective view of the back frame and the assembly of  FIG. 2 . 
         FIG. 6  is an enlarged partial perspective view of the back frame and the assembly of  FIG. 5 . 
         FIG. 7  is a perspective view of the actuator of  FIGS. 2-6 . 
         FIG. 8  is a partially exploded perspective view of the actuator of  FIG. 7 , showing a chassis, a drive mechanism, and a cover. 
         FIG. 9A  is a perspective view of the chassis and the drive mechanism of the actuator of  FIGS. 7 and 8  with the drive mechanism shown in a first position. 
         FIG. 9B  is an another perspective view of the actuator of  FIG. 9A  with the drive mechanism shown in a second position. 
         FIG. 10A  is a perspective view of an assembly for adjusting the lumbar region of the seat of  FIG. 1  according to another embodiment of the present invention, showing an actuator with a drive mechanism employing a cam and shown in a first position. 
         FIG. 10B  is an enlarged partial perspective view of the actuator of the assembly of  FIG. 10B  with the drive mechanism and cam shown in a second position. 
         FIG. 11  is a perspective view of an assembly for adjusting the lumbar region of the seat of  FIG. 1  according to yet another embodiment of the present invention having an actuator with a drive mechanism shown in phantom. 
         FIG. 11A  is an enlarged view of the assembly of  FIG. 11 , showing additional detail of the actuator. 
         FIG. 12  is rotated perspective view of the assembly of  FIG. 11 . 
         FIG. 13A  is a partial schematic top-side sectional view of the back frame and a portion of the assembly according to one embodiment of the invention shown with the seat support in the first lumbar position and with the actuator in a first position. 
         FIG. 13B  is an another partial schematic top-side sectional view of the back frame and the assembly of  FIG. 13A  shown with the seat support in the second lumbar position and with the actuator in a second position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference now to the Figures, wherein like numerals indicate like parts throughout the several views, a seat is shown at  20  in  FIG. 1 . The seat  20  is configured to be mounted in a passenger compartment of a vehicle, generally indicated at  22 , and is used to accommodate, secure, and support an occupant of the vehicle  22 . To that end, the seat  20  includes a base, generally indicated at  24 , and a back, generally indicated at  26 . The base  24  accommodates and provides support to the occupant&#39;s buttocks and thighs. Similarly, the back  26  accommodates and provides support to the occupant&#39;s shoulders, back, waist, and/or hips. The base  24  and/or the back  26  may include bolsters  28  configured to provide lateral support to the occupant so as to urge or otherwise hold the occupant in a seated position on the seat  20 . For example, the bolsters  28  may be sized, shaped, and/or oriented so as to prevent the occupant from moving laterally relative to the base  24  and/or the back  26 . 
     The back  26  is pivotally attached to the base  24  such that the occupant can selectively adjust the angular position of the back  26  with respect to the base  24  (not shown in detail, but generally known in the related art). In the representative embodiment illustrated herein, the base  24  is operatively attached to the vehicle  22  via one or more slider assemblies, generally indicated at  30  which, in turn, are secured to a floorboard  32  of the vehicle  22 . The slider assemblies  30  are configured to facilitate selective movement of the seat  20  with respect to the vehicle  22  floorboard  32  so as to effect selective legroom adjustment to accommodate differently-size occupants. By way of non-limiting example, where the seat  20  is used to accommodate an operator of the vehicle  22 , the slider assemblies  30  allow the operator to move the seat  20  closer-to or further-away-from the vehicle  22  controls, such as the accelerator, brakes, and/or steering wheel (not shown, but generally known in the art), and may be manually-adjusted or power-adjusted. However, those having ordinary skill in the art will appreciate that the seat  20  could accommodate any occupant of the vehicle  22  and, thus, could be positioned in any suitable location (i.e., driver seat, front passenger seat, rear seat, etc.) secured to any suitable portion of the vehicle  22  in any suitable way, with or without the use of slider assemblies  30 , without departing from the scope of the present invention. Moreover, while the vehicle  22  described herein is an automobile, those having ordinary skill in the art will appreciate that the vehicle  22  could be of any suitable type without departing from the scope of the present invention. By way of non-limiting example, the vehicle  22  could be adapted for civilian, commercial, industrial, military, or law enforcement use on land, water, or in the air. 
     The base  24  and back  26  of the seat  20  each include frames that provide structural rigidity and support to the seat  20  and facilitate connection between various components of the seat  20  as well as connection to the vehicle  22 , and may extend within the bolsters  28  so as to support foam and/or cushions supported in the base  24  and/or the back  26  (not shown in detail, but generally known in the related art) underneath one or more outer upholstery covers of the seat  20 , generally indicated at  34 . Typically, frames are formed of metal, but could be formed or otherwise manufactured from any suitable material sufficient to provide proper support for the occupant. The base  24  of the seat  20  includes a base frame (not shown) supported therein adapted to connect the base  24  to the slider assemblies  30 , and the back  26  of the seat  20  includes a back frame  36  supported therein (see  FIG. 1 ). The back frame  36  includes a top cross support  38  and a bottom cross support  39  spaced from and aligned substantially parallel to the top cross support  38 . The back frame  36  further includes first and second side supports  40 ,  42  extending between the top cross support  38  and bottom cross support  39  to define a periphery of the back frame  36 . 
     Referring now to  FIGS. 1-9B , an assembly  44  according to the present invention is mounted within the back frame  36  of the back  26  of the seat  20  for adjusting a lumbar region of the seat  20 , generally indicated at  46 . To that end, the assembly  44  includes a seat support  48 , an actuator  50 , a wire  52 , a conduit  54 , a first guide  56 , a second guide  58 , and an intermediate mounting device  60  which cooperate to facilitate selective adjustment of the lumbar region  36  of the seat  20 . Each of these components will be described in greater detail below. 
     The seat support  48  is adapted for suspension in the back frame  36  of the seat  20  and is selectively movable between a first lumbar position  48 A and a second lumbar position  48 B (see  FIGS. 13A-13B ). The actuator  50  is operatively attached to the seat support  48  and concurrently moves with the seat support  48  between the lumbar positions  48 A,  48 B. To that end, the actuator  50  has a chassis  62  and a drive mechanism  64  for selectively moving the wire  52  with respect to the chassis  62 . The wire  52  extends between first and second longitudinal ends  52 A,  52 B. The first longitudinal end  52 A of the wire  52  operatively engages the drive mechanism  64  of the actuator  50 . The second longitudinal end  52 B of the wire  52  is adapted for attachment to the back frame  36  of the seat  20 . The conduit  54  is disposed about at least a portion of the wire  52  and has first and second conduit ends  54 A,  54 B. The first conduit end  54 A of the conduit  54  is coupled to the actuator  50  (see  FIG. 2 ). The first guide  56  is mounted to the seat support  48  adjacent to the second end  52 B of the wire  52  with a portion of the wire  52  slidably supported by the first guide  56 . Similarly, the second guide  58  is mounted to the seat support  48  spaced from the first guide  56  with a portion of the wire  52  slidably supported by the second guide  58 . The intermediate mounting device  60  has a mount  62  adapted for attachment to the back frame  36  of the seat  20 . A portion of the wire  52  is supported by the intermediate mounting device  60 , and the second conduit end  54 B of the conduit  54  is mounted to the intermediate mounting device  60  such that predetermined movement of the drive mechanism  64  of the actuator  50  moves the wire  52  relative to the guides  56 ,  58  and the intermediate mounting device  60  so as to facilitate movement of the first guide  56  relative to the second end  52 B of the wire  52  and movement of the second guide  58  relative to the intermediate mounting device  60 , thereby effecting corresponding movement of the seat support  48  between the lumbar positions  48 A,  48 B (see  FIGS. 13A-13B ). 
     As shown best in  FIGS. 2-2A , the intermediate mounting device  60  is spaced from the seat support  48 . Specifically, the intermediate mounting device  60  guides the wire  52  from the conduit  54  towards the guides  56 ,  58 , but does not move with respect to the back frame  36  of the seat  20  as the drive mechanism  64  of the actuator  50  moves the wire  52  to effect corresponding movement of the seat support  48  between the lumbar positions  48 A,  48 B, as noted above. Moreover, the intermediate mounting device  60  remains spaced from the guides  56 ,  58  along the wire  52  as the seat support  48  moves between the lumbar positions  48 A,  48 B. 
     As shown throughout the drawings, the wire  52  is continuous between the longitudinal ends  52 A,  52 B and extends slidably through the conduit  54 , the guides  56 ,  58 , and the intermediate mounting device  60 . Thus, the wire  52  at least partially passes through the conduit  54 , the guides  56 ,  58 , and the intermediate mounting device  60 . In one embodiment, the intermediate mounting device  60  includes a device body, generally indicated at  68 , which encloses at least a portion of the wire  52 . As shown best in  FIG. 2A , the device body  68  has a substantially curved profile shaped to direct the wire  52  at least partially towards the guides  56 ,  58 . The mount  66  of the intermediate mounting device  60  extends from and merges with the device body  68 . 
     In one embodiment, the wire  52  includes a first hook  70  coupled to the second end  52 B of the wire  52 , and the mount  66  of the intermediate mounting device  60  includes a second hook  72  (see  FIG. 3 ). The hooks  70 ,  72  are spaced from each other and are adapted for attachment to the back frame  36  of the seat  20 , such as disposed in holes  74  defined in respective side supports  40 ,  42  of the back frame  36  (see  FIG. 2 ). However, those having ordinary skill in the art will appreciate that second end  52 B of the wire  52  and the mount  66  of the intermediate mounting device  60  could be configured differently and could attach to the back frame  36  of the seat  20  in a number of different ways, with or without the use of hooks  70 ,  72  without departing from the scope of the present invention. Further, as will be appreciated from the subsequent description of the actuator  50  below, the wire  52  could be of any suitable type, manufactured from any suitable material, sufficient to move through the conduit  54 , the guides  56 ,  58 , and the intermediate mounting device  60 , without departing from the scope of the present invention. By way of non-limiting example, the wire  52  could be realized as a solid wire, as a braided wire, or as a stranded wire. 
     As noted above, the seat support  48  is adapted for suspension in the back frame  36  of the seat  20 . In the representative embodiment illustrated herein, the seat support  48  is mounted within the back frame  36  of the back  26  of the seat  20  and provides adjustable lumbar support to the occupant in the lumbar region  36 . More specifically, as noted above, the seat support  48  and the actuator  50  move together between the lumbar positions  48 A,  48 B, adjacent to the lumbar region  36  of the seat  20 , in response to movement of the drive mechanism  64  of the actuator  50 , as described in greater detail below. As shown best in  FIGS. 1 and 2 , the seat support  48  is a mat-type wire mesh configured to resiliently support the back  26  of the seat  20  so as to provide support to the vehicle  22  occupant. To that end, the seat support  48  includes a plurality of horizontal rods  76  and a plurality of vertical rods  78  supporting the horizontal rods  76 . The seat support  48  also includes a plurality of rod hooks  80  formed with the horizontal rods  76  and extending from the vertical rods  78  to the side supports  40 ,  42  of the back frame  36  so as to suspend the seat support  48  therein. The horizontal rod hooks  80  extend at a constant length beyond the vertical rods  78 , thereby maintaining proper separation between the back frame  36  and the seat support  48  above the lumbar region  36  of the seat  20 . However, as shown in  FIG. 2 , rod hooks  80  may also be integrally formed with the vertical rods  78 , and may extend to the cross supports  38 ,  39  of the back frame  36  so as to suspend the seat support  48  therein. As shown in  FIG. 2 , the rod hooks  80  attach to the back frame  36  within the back  26  of the seat  20  and are spaced from the upholstery cover  34  so as to provide space for the foam or cushion between the seat support  48  and upholstery cover  34 , as noted above. 
     In one embodiment, the seat support  48  of the assembly  44  includes a first vertical rod  78 A and second vertical rod  78 B spaced longitudinally from the first vertical rod  78 A. Here, the first guide  56  is coupled to the first vertical rod  78 A, and the second guide  58  is coupled to the second vertical rod  78 B. More specifically, in one embodiment, the first guide  56  includes a first guide mount  82  coupled to the seat support  48  at a first location  84  defined by the first vertical rod  78 A, and the second guide  58  includes a second guide mount  86  coupled to the seat support  48  at a second location  88  defined by the second vertical rod  78 B. The first location  86  is spaced from the second location  88 . As shown best in  FIGS. 2A-2B , the guide mounts  82 ,  86  have a substantially c-shaped profile configured for snap attachment to the vertical rods  78  of the seat support  48 . Similarly, as shown in the embodiment of the assembly  44  illustrated in  FIGS. 11-11A , the chassis  62  of the actuator  50  may include at least one securing feature, generally indicated at  90 , configured for attaching the actuator  50  to the vertical rods  78  of the seat support  48 , such as via snap attachment. Moreover, while the representative embodiment of the securing feature  90  illustrated in  FIG. 11  is realized as a protrusion integrally formed with and extending from the chassis  62  that is clipped onto one of the vertical rods  78  of the seat support  48 , it will be appreciated that the securing feature  90  could be formed, configured, oriented, or otherwise realized in any suitable way by any suitable structural feature or component sufficient to secure the actuator  50  to the seat support  48  as described above, without departing from the scope of the present invention. Further, those having ordinary skill in the art will appreciate that the actuator  50  of the assembly  44  can be arranged, oriented, or otherwise supported in any suitable way sufficient to move concurrently with the seat support  48  between the lumbar positions  48 A,  48 B. Similarly, one or more additional securing mechanisms, generally indicated at  92 , could be utilized to secure or otherwise position other portions of the assembly  44 , such as one or more “zip ties”  92  employed to secure the conduit  54  to the seat support  48  spaced from the actuator  50  (see  FIG. 3 ). 
     As noted above, movement of the wire  52  via the drive mechanism  64  of the actuator  50  effects movement of the seat support  48  between the lumbar positions  48 A,  48 B as the wire  52  moves though the conduit  54 , the guides  56 ,  58 , and the intermediate mounting device  60  (see  FIGS. 13A-13B ). As described in greater detail below, the assembly  44  of the present invention can be implemented, oriented, or configured in a number of different ways depending on the specific configuration of the seat. Moreover, the drive mechanism  64  of the actuator  50  of the assembly  44  can be configured in a number of different ways sufficient to move the wire  52  to effect movement of the seat support  48  between the lumbar positions  48 A,  48 B, as noted above. 
     In one embodiment, the drive mechanism  64  of the actuator  50  includes a drive block, generally indicated at  94 , which is selectively movable with respect to the chassis  62  of the actuator  50  between a first position  94 A corresponding to the first lumbar position  48 A (see  FIG. 13A ), and a second position  94 B corresponding to the second lumbar position  48 B (see  FIG. 13B ). Here, as the drive block  94  moves from the first position  94 A (see  FIG. 9A ) to the second position  94 B (see  FIG. 9B ), the wire  52  correspondingly moves through the conduit  54 , the guides  56 ,  58 , and the intermediate mounting device  60  so as to effect movement of the seat support  48  between the lumbar positions  48 A,  48 B (see  FIGS. 13A-13B ). To that end, in one embodiment, the intermediate mounting device  60  is arranged along the wire  42  adjacent to the second guide  58  such that movement of the drive block  94  from the first position  94 A towards the second position  94 B urges the second guide  58  towards the intermediate mounting device  60  as the seat support  48  moves from the first lumbar position  48 A towards the second lumbar position  48 B. Similarly, in one embodiment, the first guide  56  is arranged along the wire  52  such that movement of the drive block  94  of the drive mechanism  64  from the first position  94 A towards the second position  94 B urges the first guide  56  towards the second end  52 B of the wire  52  as the seat support  48  moves from the first lumbar position  48 A towards the second lumbar position  48 B. 
     In the representative embodiments illustrated in  FIGS. 2-11B and 13A-13B , the first end  52 A of the wire  52  is fixed to the drive block  94  of the drive mechanism  64  of the actuator  50  for concurrent movement therewith, and the first conduit end  54 A of the conduit  54  is fixed to the chassis  62  of the actuator  50  at a location spaced from the drive block  94  of the drive mechanism  64 . Here, movement of the drive block  94  directly moves the wire  52  through the conduit  54 , the intermediate mounting device  60 , and the guides  56 ,  58  so as to effect movement of the seat support  48  between the lumbar positions  48 A,  48 B, as noted above. In the embodiment illustrated in  FIGS. 10A-10B , however, the drive mechanism  64  of the actuator  50  further includes a cam, generally indicated at  96 , which is fixed to the drive block  94  for concurrent movement, and the cam  96  engages a portion of the wire  52  spaced from and adjacent to the first end  52 A of the wire  52 . Here, the first end  52 A of the wire  52  does not move concurrently with the drive block  94  and is fixed to the drive mechanism  64  at a location spaced from the drive block  94 , whereby movement of the wire  52  through the conduit  54 , guides  56 ,  58 , and intermediate mounting device  60  is effected as the cam  96  moves into engagement with the portion of the wire  52  adjacent the first end  52 A, which slides within or otherwise along the cam  96  as the drive block  94  moves between the positions  94 A,  94 B. Those having ordinary skill in the art will appreciate that the specific configuration of the cam  96  and drive block  94  can be adjusted for specific application requirements, such as to optimize mechanical advantage based on the geometry of the cam  96  and the movement of the drive block  94 . It will be appreciated that the drive block  94  can be configured, supported, and/or shaped in any suitable way sufficient to effect movement of the wire  52  as described above, without departing from the scope of the present invention. 
     Referring now to  FIGS. 7-9B , in one embodiment, the actuator  50  further includes a driver, generally indicated at  98 , and a screw drive  100 . The driver  98  provides a source of rotational torque in opposing first and second rotational directions  98 A,  98 B. In one embodiment, the driver  98  is realized as an electric motor. However, it will be appreciated that the driver  98  could be realized by any suitable type of automated prime mover without departing from the scope of the present invention. 
     The screw drive  100  is supported on the chassis  62  and is disposed in torque-translating relationship with the driver  98 . Here, the drive block  94  is supported in threaded engagement with the screw drive  100  such that rotation of the driver  98  in the first rotational direction  98 A urges the drive block  94  so as to move the drive mechanism  64  from the first position  94 A toward the second position  94 B, and rotation of the driver  98  in the second rotational direction  62 B urges the drive block  94  so as to move the drive mechanism  64  from the second position  94 B toward the first position  94 A. To that end, the screw drive  100  includes an externally-threaded rod  102  extending along a portion of the chassis  62  which engages a corresponding internally-threaded portion  104  of the drive block  68  so as to linearly move the drive block  94  and the drive mechanism  64  between the positions  94 A,  94 B in response to predetermined rotation of the driver  98 . It will be appreciated that the specific configuration of the threaded engagement of the screw drive  100  between the threaded rod  102  and the threaded portion  104 , such as the pitch, thread count, etc., may be configured to correspond to force output of the actuator  50  necessary to facilitate movement between the lumbar positions  48 A,  48 B, based on available torque output of the driver  98  and structural characteristics of the seat support  48  and/or the back frame  36  of the seat  20   
     In one embodiment, the actuator  50  further includes a geartrain, generally indicated at  106 , interposed in torque-translating relationship between the driver  98  and the screw drive  100 . In the representative embodiment illustrated herein, the geartrain  106  includes worm gear  108  coupled to the threaded rod  102  of the screw drive  100  via a coupling, generally indicated at  110 , which engages a worm shaft of the driver  98  (worm shaft not shown, but generally known in the art). As shown in  FIGS. 7 and 8 , the actuator  50  may also include a cover  112  encapsulating the drive mechanism  64 , the drive block  94 , the screw drive  100 , and/or the geartrain  106 . 
     With reference now to  FIGS. 11-13B , in one embodiment, the assembly  44  further includes a sheath  114  slidably supported along the wire  52  and disposed between the guides  56 ,  58 . As shown best in  FIG. 11A , the sheath  114  is spaced from the guides  56 ,  58 . The sheath  114  provides support to the wire  52  and helps guide the wire  52  between the guides  56 ,  58  across the seat support  58 . 
     In this way, the assembly  44  of the present invention provides for selective adjustment of the lumbar region  46  of the seat  20  while affording significantly optimized and space-efficient component packaging and, at the same time, reduces the cost and complexity of manufacturing and assembling lumbar adjustment mechanisms for seats  20 . 
     The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.