Abstract:
A head restraint assembly includes a one-piece armature including a cross member having an offset portion. Also included is a ratcheting mechanism having a pivot plate directly and fixedly engaged with the offset portion of the cross member. Further included is a pivot pin extending through an aperture defined by the pivot plate and tangentially contacting a forward portion of the one-piece armature.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This patent application claims priority to U.S. Provisional Application No. 62/260,860, filed Nov. 30, 2015, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The subject matter disclosed herein relates to head restraint assemblies. 
       BACKGROUND 
       [0003]    Many vehicles, such as automobiles, include a headrest or head restraint atop an occupant&#39;s seat and in a position adjacent the occupant&#39;s head. Head restraints are typically cushioned for comfort, are height adjustable, and most are commonly finished in the same material as the rest of the seat. Design and assembly of head restraints require consideration of assembly structural integrity. Several challenges are involved with ensuring the desired structural integrity. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0004]    According to an embodiment of the invention, a head restraint assembly including an armature that includes a cross member having an offset portion. Also included is a frame. Further included is a first side structure operatively coupled to the frame. Yet further included is a second side structure operatively coupled to the frame. Also included is an upper ratchet member rigidly coupled to at least one of the first side structure and the second side structure. Further included is a pivot plate having a forked interface, the forked interface engaged with the offset portion of the cross member. Yet further included is a lower ratchet member operatively coupled to the pivot plate and selectively engaged with the upper ratchet member. Also included is a pivot pin extending through respective apertures of the pivot plate, the first side structure and the second side structure, the pivot pin tangentially contacting a forward portion of the armature. 
         [0005]    According to another embodiment of the invention, a head restraint assembly includes a one-piece armature including a cross member having an offset portion. Also included is a ratcheting mechanism having a pivot plate directly and fixedly engaged with the offset portion of the cross member. Further included is a pivot pin extending through an aperture defined by the pivot plate and tangentially contacting a forward portion of the one-piece armature. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0007]      FIG. 1  is a front perspective view of a head restraint assembly; 
           [0008]      FIG. 2  is a rear perspective view of the head restraint assembly with a cover removed, illustrating various components of the head restraint assembly shrouded within a core; 
           [0009]      FIG. 3  is a rear, perspective view of the ratcheting mechanism with the core removed; 
           [0010]      FIG. 4  is a vertical center section view of the head restraint assembly, illustrating the internal ratcheting mechanism assembly; 
           [0011]      FIG. 5  is an enlarged vertical center section view of the internal ratcheting mechanism; 
           [0012]      FIG. 6  is a front, perspective view of the ratcheting mechanism with the core removed; 
           [0013]      FIG. 7  is a perspective view of the assembled ratcheting mechanism; 
           [0014]      FIG. 8  is a disassembled, perspective view of the ratcheting mechanism; 
           [0015]      FIG. 9  is a perspective view of the head restraint assembly according to another aspect of the disclosure; and 
           [0016]      FIG. 10  is a perspective view of the head restraint assembly according to the embodiment illustrated in  FIG. 9 . 
       
    
    
       [0017]    The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. 
       DETAILED DESCRIPTION 
       [0018]    Referring to  FIGS. 1 and 2 , a head restraint assembly  10  is schematically depicted. The head restraint assembly  10  includes a base portion  14  (which may also be referred to as an “armature”) that is mountable to a vehicle seat (not shown), and, more specifically, to the upper portion of the seatback of the vehicle seat. In the embodiment depicted, the base portion  14  is formed from a single piece of metal and includes two parallel post portions  18  that are mounted, or mountable, to the top of the seatback of the vehicle seat, as understood by those skilled in the art. Each of the post portions  18  includes a respective elongated, straight portion  22 . Each of the straight portions  22  extends into a respective hole formed in the top of the seatback to attach the head restraint assembly  10  to the vehicle seat. 
         [0019]    The head restraint assembly  10  further includes a head restraint  40  operatively connected to base portion  14 . In the embodiment depicted, the head restraint  40  includes a frame  44  that shrouds the internal mechanism of the head restraint  40 . In one embodiment, the frame  44  is a protective expandable polyurethane (EPP) core. The head restraint  40  also includes cushion (not shown) and a flexible trim (not shown) that are mounted with respect to the frame  44  for movement therewith. The head restraint cushion is comprised of a soft foam or a like material to provide a cushion between the head of a human occupant to the vehicle seat and the head restraint frame  44 . The head restraint trim covers at least part of the cushion and the frame to enhance the aesthetics and comfort of the head restraint. Exemplary cover materials include cloth, vinyl, leather, etc. 
         [0020]    Referring to  FIG. 3 , the base portion  14  also includes a cross-member portion  26  that interconnects the two post portions  18 . When the base portion  14  is connected to an upright vehicle seat, the post portions  18  are generally vertical, and the cross-member portion  26  is generally horizontal. The cross-member portion  26  includes segments  30 A,  30 B,  32 A,  32 B,  34 A,  34 B, and  36 . When the base portion  14  is connected to an upright vehicle seat, each of segments  30 A,  30 B extends forwardly from an upper end of a respective one of the post portions  18 , each of segments  32 A,  32 B extends transversely from a respective one of the segments  30 A,  30 B, each of segments  34 A,  34 B extends rearward from a respective one of the segments  32 A,  32 B, and segment  36  extends transversely to interconnect segments  34 A and  34 B and runs parallel to segments  32 A,  32 B. Segments  32 A,  32 B are coaxial with each other and segments  34 A,  34 B,  36  form a U-shaped bend or offset in the cross-member portion  26  between linear, coaxial segments  32 A,  32 B. The above-described orientation of the cross-member portion is merely illustrative. Additionally, more or fewer segments may be included. 
         [0021]    Referring to  FIGS. 4 and 5 , a ratcheting pivot mechanism  134  includes pivoting body  150  and a lower stamping pivot plate  152  that may be pivotally interconnected using a pivot pin  262 . A movable lower ratchet member  156  is pivotally connected to the lower stamping pivot plate  152 , and is selectively positionable by the upper ratchet member  158  that is affixed or integrated into the pivoting body  150  (for clarity, upper ratchet member  158  may herein be referred to as the “fixed ratchet member  158 ”). When the movable lower ratchet member  156  is engaged with the fixed ratchet member  158  (i.e., when the teeth  160  of the movable ratchet member  156  contact the teeth  161  of the fixed ratchet member  158 ), the pivoting body  150  (and coupled head rest frame  44 ) may be permitted to rotate in a forward direction, but are not permitted to rotate in a rearward direction. To facilitate this one way motion, each ratchet  156 ,  158  has respective teeth  160 ,  161  that may interconnect with the teeth of the opposing ratchet and may advance in a step-wise manner. 
         [0022]    The pivot mechanism further includes a spring  162  ( FIG. 8 ) disposed between the lower stamping pivot plate  152  and the movable lower ratchet member  156 . As will be described in greater detail below, the spring  162  may be configured and/or positioned in a manner where it applies separation load to the movable lower ratchet member  156  from the lower stamping pivot plate  152 , promoting the lower ratchet member  156  to engage with the fixed upper ratchet member  158 . And when the spring  162  is positioned where it applies a reversed separation load to the movable lower ratchet member  156  from the lower stamping pivot plate  152 , promoting the lower ratchet member  156  to disengage with the fixed upper ratchet member  158  (i.e., when the teeth  160  of the movable lower ratchet member  156  loses contact with the teeth  160  of the fixed upper ratchet member  158 ). As such, there may be an over center position where the direction of the biasing provided by the spring  162  may switch between an engaging and disengaging direction. 
         [0023]    The pivoting body  150  houses all the internal mechanism components within cavity  58 , created by a series of formed offset assembly surfaces flanked by front and rear strength flanges  48 ,  52  such that the pivoting body  150  moves in unison with the frame  44  as it rotates. The pivoting body  150  may be used to toggle the movable lower ratchet member  156  between an engaged state and a disengaged state while articulating through its full pivoting range. To accomplish this toggling, the movable lower ratchet member  156  may include a reset emboss pin or the like (not shown) that may be rigidly coupled with the lower ratchet member  156 , and that may interact with a reset window defined within the pivoting body  150 . As the pivoting body  150  articulates relative to the lower stamping pivot plate  152 , the reset pin may contact the perimeter of the reset window, which may apply a selective force to the pin. As such, the interaction between the reset window and the reset pin may urge the movable lower ratchet member  156  to move between the engaged position and the disengaged position. In alternative embodiments, other mechanical interference means may be used to transition the movable lower ratchet member  156  between the engaged position and the disengaged position. Such interference mechanisms, for example, may include the use of catches, pins, rockers, or other similar devices known in the art. 
         [0024]    In operation, when the movable lower ratchet member  156  is engaged with the fixed upper ratchet member  158 , the pivoting body  150  may be free to articulate in a forward direction, however, any movement in a rearward direction may be restrained by the interaction of the gear teeth  160  of the respective ratchet members  156 ,  158 . 
         [0025]    The reversible bias of spring  162 , which may cause a “toggling” effect of the movable lower ratchet member  156 , may result from the geometric arrangement of the spring  162 , movable lower ratchet member  156 , and lower stamping pivot plate  152 . The movable lower ratchet member  156  may pivot with respect to the lower stamping pivot plate  152  at a point  178 . Spring  162 , such as for example, an omega-shaped spring  162 , may then extend between the movable lower ratchet member  156  and the lower stamping pivot plate  152 , and may generally exert an opposite, outward force against each respective component. 
         [0026]    The spring force applied to the movable lower ratchet member  156  by spring  162  may urge the lower ratchet member  156  to pivot either in an engaging or disengaging direction relative to the pivot point  178 , according to its alignment with the radial axis. When the movable lower ratchet member  156  is in an engaged position, the spring force acts on the movable lower ratchet member  156  in a direction that would cause the lower ratchet member  156  to rotate in a clockwise (engaging) direction. When the movable lower ratchet member  156  is in a disengaged position, the spring force is applied in a direction that would cause the lower ratchet member  156  to rotate in a counter-clockwise (disengaging) direction. 
         [0027]    With such a spring configuration, there exists a position between the engaged and disengaged position where the spring force may be perfectly aligned with the radial axis, and no biasing force is applied. This “neutral” position is generally an un-stable position and is commonly referred to as the “over-center” position. As such, the movable lower ratchet member  156  in this configuration is bistable—that is, it is stable in two positions: either engaged or disengaged. 
         [0028]    The mechanism  134  may be similar to the mechanism shown and described in commonly-assigned U.S. patent application Ser. No. 13/042,818, filed Mar. 8, 2011, (published as 2011/0221250 on Sep. 15, 2011) and which is hereby incorporated by reference in its entirety. 
         [0029]    The lower stamping pivot plate  152  includes a forked portion  250  formed by two parallel, protuberant arms  254 . The arms  254  define a groove  258  therebetween, and the lower stamping pivot plate  152  is positioned such that segment  36  of the base portion  14  extends through the groove  258 . The arms  254  are partially covered by an elastomeric covering material  268  to prevent metal-to-metal contact between the pivot arm  152  and segment  36 , and to provide a snug fit between the pivot arm  152  (i.e., arms  254 ) and segment  36 , thereby eliminating rattle. The lower stamping pivot plate  152  does not rotate relative to the base portion  14  when the head restraint  40  is rotated, but lateral movement of the lower stamping pivot plate  152  relative to the base portion  14  is permitted. This interface between the lower stamping pivot plate  152  and the base portion  14 , which restricts or prevents relative rotation therebetween, is significantly easier to assemble and manufacture, and is less expensive, than prior art head restraints. 
         [0030]    Referring to  FIGS. 6-8 , the pivot pin  262  extends through a hole  276  in the lower stamping pivot plate  152  and through holes formed in stampings  320 ,  324 . The pivot pin  262  is operatively and rigidly connected to the base portion  14 . More specifically, the pivot pin  262  is rigidly connected to segments  32 A and  32 B of the base portion  14 . As shown, the pivot pin  262  extends outward of segments  34 A and  34 B of the base portion to connect with segments  32 A,  32 B. The elongated nature of the pivot pin  262  and the rigid connection to the base portion enhances structural integrity of the overall head restraint assembly. In the illustrated embodiment, the pin is rigidly connected to a forward portion of segments  32 A,  32 B. It is to be appreciated that connection to upper, lower or rearward portions of these segments is contemplated. 
         [0031]    The stampings  320 ,  324  are the two main side stampings that pivoting body  150  are comprised, and house all the internal mechanism componentry. The upper ratchet member  158 , lower ratchet member  156 , spring  162 , and lower stamping pivot plate  152  are all assembled between the stampings  320 ,  324 . The pivot pin  262  and the hole  276  are not circular, and thus the pivot pin  262  does not rotate with respect to the lower stamping pivot plate  152 . The pivot pin  262  defines a first hole  400  located on an outer side of stamping  320  and a second hole  402  on an outer side of stamping  324 . The head restraint  40  includes two torsional springs  136 ; each of the springs  136  is coiled around the pivot pin  262  on a respective side of the stampings  320 ,  324 . Each spring  136  has a respective end disposed within a respective hole  400 ,  402  to establish connectible rotation of the springs  136  to the pivot pin  262 . The springs  136  maintain a rearward bias on the head restraint  40 ; that is, the springs  136  urge the head restraint  40  in the rearward rotational direction, and are thus referred to as “return springs.” 
         [0032]    Referring to  FIGS. 9 and 10 , it is to be understood that the stampings  320 ,  324  are side structures that are generally referred to as a first side structure and a second side structure herein. The side structures  420 ,  424  in the illustrated embodiment are formed of plastic structures. 
         [0033]    Typical pivoting fore-aft adjustable headrests available today require some kind of welding, riveting or some other means of hard fixing its ratcheting mechanism to the armature or lower sub-assembly  14 . The embodiments disclosed herein greatly reduce and/or eliminate all previous mentioned procedures and lowers the overall weight of the headrest at the same time. Welding the lower stamping pivot plate  152  to a lock post and then riveting it to the center pivot shaft and slave leg to create the lower mechanism assembly has been replaced with a modified lower stamping pivot plate  152  and a one piece armature  14 . 
         [0034]    While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.