Patent Publication Number: US-2005127735-A1

Title: Vehicle seat with adjustable support system

Description:
RELATED APPLICATIONS  
      The present patent document claims the benefit of the filing date under 35 U.S.C. §119(e) of provisional U.S. patent application Ser. No. 60/517,311, filed Nov. 3, 2003, which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to an elastomeric seating system. More particularly, the present invention relates to an elastomeric seating system having elements such as an elastomeric headrest, a metal support frame and a backrest/seat cover.  
     BACKGROUND  
      The present invention relates generally to seat components. More particularly, this invention pertains to a seating structure and/or components attached to a seat incorporating an elastomeric membrane.  
      Office chairs typically include a rigid frame surrounded by a single-layer or multi-layer foam and then covered with cloth, leather or the like. This type of upholstered seating creates a deformable cushion which conforms to the user&#39;s body. These upholstered seats are often used in automobiles, airlines, marine applications, office furniture and other known applications.  
      A woven fabric such as an elastomeric membrane for use in a seating structure has been disclosed in U.S. Pat. No. 6,035,901 and related patents assigned to Herman Miller Inc. This seating structure has greatly enhanced the comfort of office chairs. The use of an elastomeric membrane represents an improvement over upholstered seats. An elastomeric membrane can more readily distribute a person&#39;s weight as they adjust their seated position, and provides more aeration in order to keep the body cooler by dissipating more body heat. In the event of damage to the seat, the flexible membrane seating structure can be easier to repair or replace than an upholstered seat. While this flexible membrane technology continues to be highly useful for office seating structures, there are other applications in which an elastomeric membrane would be useful. For example, an elastomeric seat is lighter than many conventional seats and therefore has inherent advantages for many new applications. Also, there is a need for the use of a flexible membrane in seating structures designed for purposes other than office seating.  
     SUMMARY OF THE INVENTION  
      The present invention is directed to an elastomeric seating system that supports various functional elements.  
      According to one aspect of the invention, a headrest for supporting the head of a user is provided. A carrier member having a central opening is connected to the headrest. An elastomeric membrane having an edge portion is connected to the carrier member and covers the central opening.  
      According to another aspect of the present invention, a seating structure is provided for use with an elastomeric membrane and an edge portion. A carrier member is also provided having a central opening. The edge portion of the elastomeric membrane is connected to the carrier member and covers the central opening. A metal support frame is connected to the carrier member.  
      According to another aspect of the invention, a seating structure is provided having a seat, a backrest, a first elastomeric membrane and a second elastomeric membrane. The first elastomeric membrane and the second elastomeric membrane each have an edge portion. The first elastomeric membrane is connected to the seat and the second elastomeric membrane is connected to the backrest. A first cover is connected to one of the seat and the backrest.  
      As used herein the term “connected to” is intended to be interpreted broadly and to include direct and indirect connections.  
      As used herein the term “seating structure” is intended to be interpreted broadly and to include seating uses in transportation applications such as automobiles, aircraft, watercraft, wheelchairs or other uses such as fixed seating in auditoriums, traditional office seating and residential uses.  
      The present invention, together with attendant objects and advantages, will be best understood with reference to the detailed description below in connection with the attached drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a front view of a headrest in accordance with a first embodiment of the present invention;  
       FIG. 2  is a rear view of a headrest in accordance with the embodiment of  FIG. 1 ;  
       FIG. 3  is a side view of the headrest as shown in  FIG. 2 ;  
       FIG. 4  is a rear view of the headrest adjustment mechanism as shown in  FIGS. 2-3 ;  
       FIG. 5  is a rear view of a second embodiment of the headrest;  
       FIG. 6  is an exploded view of an embodiment of a support mechanism for the headrest;  
       FIG. 7  is an upper perspective view of a third embodiment of the headrest of the present invention;  
       FIG. 8  is a front perspective view of an embodiment of an elastomeric seating structure of the present invention with a metal support housing;  
       FIG. 9  is an exploded view of a carrier member;  
       FIGS. 10A  &amp; B illustrate embodiments of a portion of the support housing;  
       FIG. 11  is a perspective view of an elastomeric seating structure according to another embodiment of the present invention illustrated in an automobile;  
       FIG. 12  is rear perspective view of another embodiment of an elastomeric seating structure illustrated in an automobile;  
      FIGS.  13  A-C illustrate three embodiments of a backrest cover with  FIG. 13 A  illustrating the backrest cover in an exploded relationship with respect to the backrest;  
       FIG. 14  is an illustration of a seating structure according to another embodiment of the present invention; and  
       FIG. 15  is an exploded view of a support plate and seat cover as shown in  FIG. 14 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      The invention is described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood by the following detailed description. However, the embodiments of this invention as described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings. It should also be understood that the drawings are not to scale and in certain instances details have been omitted which are not necessary for an understanding of the present invention, such as conventional details of fabrication and assembly. In addition, like elements have been numbered identically in the different embodiments.  
       FIGS. 1-7  illustrate elastomeric headrests  10 ,  12 ,  14  according to three embodiments of the present invention. The elastomeric headrests  10 ,  12 ,  14  of the present invention have a number of advantages. For example, the elastomeric headrest  10  provides greater comfort for the head of a user while also providing for aeration to more readily dissipate heat. In addition, the headrest  10  has less weight than many conventional headrests and can be more economically manufactured. By having less weight, the headrest  10  (in combination with the other elastomeric elements, e.g., the seat and backrest) can help provide increased fuel economy in an automobile or other vehicle. Further, the headrest  10  does not block visual access and is also readily cleaned.  
      The first embodiment of the elastomeric headrest  10  is illustrated in  FIG. 1 . The headrest  10  includes a carrier member  20  and elastomeric material  22 . For a further description of the elastomeric material  22 , reference is made to U.S. Pat. No. 6,035,901, entitled “Woven Seating Fabric For a Seating Surface” filed in the names of William Stumpf et al. and issued on Mar. 14, 2000, the disclosure of which is hereby incorporated by reference. In one embodiment, the elastomeric material  22  is molded to the carrier member  20 . However, it should be recognized that alternate known attachment methods may be used to secure the elastomeric material  22  to the carrier member  20 .  
       FIGS. 2-4  illustrate side and rear views of the elastomeric headrest  10  and the adjustment structure  30 . The adjustment structure  30  includes a body  40  connected to the carrier member  20  at a pivotable connection point  42 . A support rod mechanism  44 , as best illustrated in  FIG. 4 , allows the body  40  to slide upward or downward therefrom in order to adjust the height of the elastomeric headrest  10  relative to a base structure. A conventional button  48  is used to secure the body  40  in a position selected by the user. In one embodiment, a conventional spring clip is used to secure the support rod mechanism  44  in the selected location. A rod  50  is connected to opposing ends of the carrier member  20  and connects to the body  40  at the pivotable connection point  42 . Conventional clips  54  are used to secure the rod  50  to the carrier  20 . The rod  50  may be formed from known materials such as plastic or metal. As a result, the elastomeric headrest  10  can be height-adjusted to suit the need of a user. In addition, as best illustrated in  FIG. 3 , the elastomeric headrest  10  may be pivoted into an angular position selected by the user. It should also be recognized, however, that elastomeric headrest  10  may also be used with a fixed support column and/or fixed angular positioning mechanism.  
      With particular reference to  FIG. 3 , the carrier member  20  has a generally inverted C-shape in the illustrated embodiment. The shape and pivotable movement of the elastomeric headrest  10  allows it to pivot back as a user moves their head backwards. Accordingly, the headrest  10  provides a “rolling” support for the head of user as their head moves backwards such as when they move to a reclining position.  
       FIGS. 5-6  illustrate a second embodiment of an elastomeric headrest  12  according to the present invention. The elastomeric headrest  12  is constructed in the same general manner and operates similarly to the elastomeric headrest  10 . However, the elastomeric headrest  12  has a slightly different adjustment structure  60 . The adjustment structure  60  includes wing portions  62 ,  64  that connect to the ends of carrier member  22 . A pivotable rod (not shown) passes through interior channel  70  within the adjustment structure  60 . The channel  70  is best illustrated in  FIG. 6  where the adjustment structure  60  is shown in an exploded view illustrating sides  60 A,  60 B. Conventional clips  71  are connected to the rod and secure it to the carrier  20 . A support rod mechanism  72 , as best illustrated in  FIG. 5 , allows the body  74  to slide upward or downward therefrom in order to adjust the height of the elastomeric headrest  12  relative to a base structure. The channels  76  ( FIG. 6 ) engage the support rod mechanism  72 . A conventional button  78  is used to secure the body  74  in a position selected by the user. A conventional spring clip could be used with the button  78  to selectably engage the support rod mechanism  72 .  
       FIG. 7  illustrates a third embodiment of an elastomeric headrest  14  according to the present invention. The elastomeric headrest  14  is constructed in the same general manner and operates similarly to the elastomeric headrest embodiments  10 ,  12 . However, the elastomeric headrest  14  has a slightly different adjustment structure  100 . The adjustment structure  100  includes curved opposing portions  102 ,  104  that connect to intermediate position  110  and  112  on the carrier member  114 . The carrier member  114  includes a tab  120  that is pivotably connected to the connector  122  on the adjustment structure  100 . The elastomeric headrest  14  is pivotable in a lateral direction to suit the needs of a particular user. The elastomeric material  22  is the same material as described above.  
      It should be recognized that the headrest could be molded as a complete structure or that a contoured ring (plastic or metal) could comprise the perimeter of the carrier. This structure would also provide a different aesthetic appearance for the headrest. The elastomeric material could also be prestreched and molded to the carrier with a desired contour with tension coming from the shrinking of the carrier during the molding process. An alternate approach includes molding the elastomeric material and carrier as a two-dimensional piece which does not require prestreching. A perimeter ring would be attached to the carrier in order to thereby stretch the elastomeric material. It should be further recognized that other attachment methods, as known to those of ordinary skill in the art may be used.  
       FIGS. 8-10  illustrate an embodiment of an elastomeric seating structure  200  having a rigid (preferably a material such as aluminum, steel magnesium, carbon fiber or other known materials) support frame  202 . The support frame  202  or under structure is intended to be fixedly secured to a base structure. In particular, the use of an elastomeric seating structure  200  is appropriate for many applications such as motor vehicle seating, aircraft seating, watercraft or marine seating or other known applications where a rigid base structure is necessary. The seating structure  200  includes carrier members  204 ,  206  connected to elastomeric materials  22  as described and referenced herein.  FIG. 8  also illustrates an adjustable back support element such as a lumbar support  210 . It should also be noted that the elastomeric material in the carrier member  204  allows a user to have visual access to beneath the seating structure. This advantage is useful in many applications such as an aircraft.  
      As illustrated in  FIG. 9 , the carrier member  204  includes a top portion  218  and a bottom portion  220 . The carrier member  204  may be formed from conventional materials such as known standard or high performance materials such as carbon fiber materials or resin materials. The top portion  218  includes a fastener receiving element or boss  219 . The bottom portion  220  includes integral columns  222  molded therein. The columns  222  include a channel  224  adapted to receive a fastening element such as a screw.  
       FIGS. 10A  &amp; B illustrate the attachment of the carrier member  204  to the support frame  202 . The support frame  202  includes a top portion  230  having apertures  232  formed in the legs  234 . A support perimeter  236  interconnects the legs  234 .  FIG. 10B  illustrates a fastening element such as a bolt  240  that is received within the boss  242 . The boss  242  is fit within the aperture  232 . The aperture  232  is threaded so as to receive the bolt  240 . Accordingly, the bolt  240  passes through the channel  224  of the bottom portion  220  of the carrier member  204  and into the support frame  202 , particularly the aperture  232 , thereby securing the assembly together.  
      It should also be recognized that the metal frame could be formed with a raised edge equal in height to the carrier  204 . The carrier  204  could then nest within the metal frame thereby providing additional structural strength to the seating structure. The back carrier  206  could also be secured through a metal seat back. Also, a fascia cover such as a soft molded material with padding could be applied to the perimeter of the support structure  202  in order to provide additional support and comfort without compromising the advantages of the elastomeric material  22 .  
       FIG. 11  illustrates an embodiment of an elastomeric seating structure  300  in a vehicle application, particularly an automobile. The seating structure  300  includes carrier members  302 ,  304  with elastomeric material  22 . A rigid support frame  310  is used to secure the carrier member  302  to a base structure. Rear support brackets  312  interconnect the seat carrier  302  to the back carrier  304 . Headrest  320  is connected to a top portion  322  of the back carrier  304 . The seating structure  300  is constructed using essentially the same elements as described above. It should be recognized that various known attachment methods and materials could be used to secure the seating structure  300 .  
       FIG. 12  illustrates another embodiment of a seating structure  350  in a vehicle application. The seating structure  350  is constructed and operates in essentially the same manner as does the embodiment  300  except for the use of a shroud or cover  352 . The cover  352  extends over the rear surface  354  of the seat back  356  and is generally contoured to fit the rear surface  354 . The cover  352  acts to protect the rear surface  354  from accidental bumping or kicking. While the illustrated embodiment is directed at an automobile, the cover  352  is useful in any application where the rear surface  354  should be protected such as in aircraft, auditoriums or public seating.  
      The cover  352  includes a perimeter  360  and a plurality of apertures  362 . The apertures  362  are sized to receive a fastening element such as a screw which will be further described herein. A plurality of vents  366  extend somewhat radially outward in the illustrated embodiment. The vents  366  allow for the seating structure  350  to retain the advantages of heat dissipation and aeration obtained by using an elastomeric material  22 .  
      FIGS.  13 A-C illustrate alternate embodiments of the covers  380 ,  382 ,  384 .  FIG. 13A  illustrates one embodiment for the connection of the cover  380  to a seat back  390 . The cover  380  includes apertures  392  sized to receive a fastening element such as a screw. Spacers  394  are located behind the apertures  392  and connect to the threaded holes  398 . The spacers  394  include a channel adapted to receive the fastening element. Accordingly, a fastener connects the assembly together by passing through the apertures  392  and the channel in the spacer  394  and into the hole  398 . Side vents  400  provide for additional air flow beneath the elastomeric material. In one embodiment, the spacers  394  have a length of approximately 1-2 inches. The use of spacers  394  is important because it allows pressure points on the elastomeric material to be distributed while also allowing air-flow beneath the elastomeric material  22 .  
       FIGS. 13B  &amp; C illustrate covers  382 ,  384  constructed in accordance with additional embodiments. The covers  382 ,  384  operate in essentially the same manner as the embodiments described above except that alternate vent configurations  402 ,  404  are illustrated. The vent configuration  402  includes a plurality of laterally arranged slots or perforations  410  and a plurality of pairs of generally radially extending slots  412 . The cover  404  includes similar slots  418  and  420  with side vents  422  also provided.  
       FIGS. 14 &amp; 15  illustrate another embodiment of a seating structure  500  with a seat shroud or cover  502 . The seat cover  502  protects the seat from inadvertent bumping and kicking in much the same way as the backrest cover described above. The seating structure  500  includes a backrest  510  and armrest  512 . Backrest cover  518  is connected to the backrest  510  using a conventional fastening element  519  and spacers  520  as generally described above. The seat  526  includes a support plate  530  and the cover  502 . The seat cover  502  is connected to the backrest cover  518  in the illustrated embodiment at the connector  532 . The connector  532  includes a conventional fastening element  536  and a spacer  538 . The connector  532  allows for a somewhat flexible connection thereby allowing the backrest  510  to flex. It should be recognized, however, that the seat cover  502  could be independently connected to the seat  526 . The seat cover  502  is connected to the support plate  530  using a conventional fastening element that passes through the apertures  540 , spacers  542  and into the support plate  530 . The seat cover  502  thereby protects the lower portion of the seat  526  while also allowing air flow therebeneath.  
      The embodiments described above and shown herein are illustrative and not restrictive. The scope of the invention is indicated by the claims rather than by the foregoing description and attached drawings. The invention may be embodied in other specific forms without departing from the spirit of the invention. For example, while an automobile application is illustrated in some of the figures, the present invention is useful in a wide variety of other known applications. Accordingly, these and any other changes which come within the scope of the claims are intended to be embraced herein.