Abstract:
A seat system having a seat back structure. The seat back structure includes a seat back structure surface. The seat back structure surface defines a plurality of corrugations. A shape of the seat back structure varies based on deflection of the plurality of corrugations.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a United States National Phase Application of International Application PCT/US2015/032167 filed May 22, 2015 and claims the benefit of priority under 35 U.S.C. §119 and §120 of U.S. Provisional Application 62/003,278 filed May 27, 2014, the entire contents of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a seat system, particularly a seat system that is provided in a motor vehicle. 
       BACKGROUND OF THE INVENTION 
       [0003]    Conventional techniques for achieving a supportive, plush and compliant seat involve the use of foam. Foam only compresses a percentage of its thickness, usually less than fifty percent. This provides a design that is not space efficient and does not provide a completely sink in feel for the user. 
       SUMMARY OF THE INVENTION 
       [0004]    An object of the present invention is provide a seat back structure of a seat system that is thin, and dynamic to provide a sink in feel for a user of the seat system. 
         [0005]    According to the invention, a seat system comprises a seat back structure. The seat back structure comprises a seat back structure surface. The seat back structure surface defines a plurality of corrugations. A shape of the seat back structure varies based on deflection of the plurality of corrugations. 
         [0006]    The seat back structure may comprise a first seat back structure position and a second seat back structure position. The seat back structure surface may comprise a first lateral length in the first seat back structure position. The seat back structure surface may comprise a second lateral length in the second seat back structure position. 
         [0007]    Each of the corrugations may have a user contact portion. The user contact portion of one of the corrugations may be located at a first distance from the user contact portion of another one of the corrugations in the first seat back structure position. The user contact portion of one of the corrugations may be located at a second distance from the user contact portion of another one of the corrugations in the second seat back structure position. The first distance may be less than the second distance. 
         [0008]    At least a portion of the seat back structure may move in a rearward direction when the seat back structure moves from the first seat back structure position to the second seat back structure position. 
         [0009]    The seat system may further comprise a seat back frame. The seat back structure may be connected to the seat back frame. The seat back structure may be a single, one-piece panel. 
         [0010]    The seat system may further comprise a suspension system connected to the seat back structure. The deflection of the corrugations may vary based on the suspension system. 
         [0011]    The seatback structure may comprise vertical sections. The suspension system may comprise an elongating system. The vertical sections may move from a first state to a second state as the suspension system elongates. 
         [0012]    The suspension system may comprise a plurality of leaf springs and at least one wire. The deflection may be based on at least a tension of the at least one wire and a resistance of the plurality of leaf springs. 
         [0013]    The suspension system may comprise a sinusoidal suspension system. The seatback structure surface may comprise vertical members. The deflection of the vertical members may be based on bending of sinusoidal wires. 
         [0014]    A tertiary component may be placed laterally of the seat back structure to control movement of vertical members of the seat back structure in a rearward direction. Forces may not be applied to the tertiary component unless the forces exceed seat input forces. 
         [0015]    The tertiary component may provide a bending movement. The bending movement may control displacement of the vertical members. 
         [0016]    The tertiary component may provide a tension. Tensile forces associated with the tertiary component may control displacement of the vertical members. 
         [0017]    The seat back structure may comprise a user contact surface and a rear surface. The user contact surface may be opposite the rear surface. At least a portion of the suspension system may be located adjacent to the rear surface. 
         [0018]    The suspension system may comprise a plurality of suspension members. Each of the leaf springs may be arranged between one of the plurality of suspension members and another one of the plurality of suspension members. 
         [0019]    The plurality of leaf springs may comprise a plurality of first leaf springs and a plurality of second leaf springs. The first leaf springs may be associated with the at least one tension adjustment means. The suspension system may comprise another tension adjustment means for adjusting a tension of the second leaf springs. 
         [0020]    The seat back structure may comprise a heating element. 
         [0021]    The seat back structure may comprise a strain gage. 
         [0022]    The seat back structure may comprise electro active polymers. 
         [0023]    The seat back structure surface may define a plurality of ducts. The ducts may provide an airflow path in a heated and cooled seat. 
         [0024]    According to the invention, a seat system comprises a seat back structure. The seat back structure comprises a plurality of interlinking sections and a plurality of vertically oriented sections. Each of the vertically oriented sections is located at a spaced location from another one of the plurality of vertically oriented sections. The plurality of interlinking sections provide a translational relationship between the vertically oriented sections. 
         [0025]    The seat back structure may comprise a user occupied seat back structure configuration and a user unoccupied seat back configuration. The seat back structure may comprise a first lateral length in the user unoccupied seat back configuration. The seat back structure surface may comprise a second lateral length in the user occupied seat back configuration. 
         [0026]    The seat system may further comprise a suspension system that is connected to the seat back structure. 
         [0027]    The suspension system may be an elongating system. The vertically oriented sections may move from a first state to a second state as the suspension system elongates. 
         [0028]    The suspension system may comprise a plurality of leaf springs and at least one wire. A deflection of the vertically oriented sections may be based on at least a tension of the at least one wire. 
         [0029]    The suspension system may comprise a sinusoidal suspension system. A deflection of the vertically oriented sections may be based on bending of sinusoidal wires. 
         [0030]    A tertiary component may be placed laterally to the seat back structure to control a rearward movement of the vertically oriented sections. Forces may not be applied to the tertiary component unless the forces exceed seat input forces. 
         [0031]    The tertiary component may provide a bending movement. The bending movement may control displacement of the vertically oriented sections. 
         [0032]    The seat system may further comprise a seat back frame. The seat back structure may be connected to the seat back frame. The seat back structure may be a single, one-piece seat back structure. 
         [0033]    According to the invention, a seat system comprises a seat back frame. A single, one-piece seat back structure is connected to the seat back frame. The single, one-piece seat back structure comprises a seat back structure surface. The seat back structure surface comprises a plurality of user engaging portions. Each of the user engaging portions is located at a spaced location from another one of the user engaging portions. The seat back structure comprises an unoccupied seat back structure position and an occupied seat back structure position. The seat back structure surface comprises a first lateral length in the unoccupied seat back structure position. The seat back structure surface comprises a second lateral length in the occupied seat back structure position. The second lateral length is greater than the first lateral length. 
         [0034]    The seat system may further comprise a suspension system connected to the seat back structure. The suspension system may comprise a plurality of leaf springs and a plurality of wires. A deflection of the seat back structure surface may be based on at least a resistance provided by the leaf springs and a tension of the plurality of wires. 
         [0035]    The seat back structure surface may be in a non-stretched configuration with the seat back structure in the unoccupied seat back structure position. The seat back structure surface may be in a stretched configuration with the seat back structure in the occupied seat back structure position. 
         [0036]    The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0037]      FIG. 1  is a perspective view of a seat system of the present invention; 
           [0038]      FIG. 2  is a partial rear view of the seat system; 
           [0039]      FIG. 3  is a partial perspective view of the seat system; 
           [0040]      FIG. 4  is an enlarged view of the seat system; 
           [0041]      FIG. 5  is another perspective view of the seat system; 
           [0042]      FIG. 6  is a partial sectional view of a seat back structure of the seat system; 
           [0043]      FIG. 7  is another partial perspective view of the seat system; 
           [0044]      FIG. 8  is yet another perspective view of the seat system; 
           [0045]      FIG. 9  is yet another perspective view of the seat system; 
           [0046]      FIG. 10  is a rear perspective view of the seat system; 
           [0047]      FIG. 11  is a top view of the seat system prior to a user engaging the seat back structure; 
           [0048]      FIG. 12  is a top view of the seat system after the user has engaged the seat back structure; 
           [0049]      FIG. 13  is a perspective view of a suspension system of the seat system; 
           [0050]      FIG. 14  is a partial perspective view of a mechanism of the suspension system; 
           [0051]      FIG. 15  is an enlarged view of a stop element of the suspension system; 
           [0052]      FIG. 16  is a perspective view of the suspension system of the seat system; 
           [0053]      FIG. 17  is another top view of the seat system; 
           [0054]      FIG. 18  is a view showing a panel affixed to a composited structure; and 
           [0055]      FIG. 19  is a sectional view of a suspension system. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0056]    Referring to the drawings in particular,  FIG. 1  is a perspective view of a seat system  1 . The seat system  1  includes a seat back structure (panel)  5  that is connected to a seat frame  3 . A headrest connecting structure  2  is connected to the seat frame  3 . The headrest connecting structure  2  allows a headrest to be connected to the seat frame  3 . The seat back structure  5  is formed of a one-piece panel that has a corrugated surface  7 . The corrugated surface  7  includes a plurality of vertically oriented members  9 . The vertically oriented members  9  define a contact surface  13  for contacting a user of the seat back structure  1 . The vertically oriented members  9  are connected by interlinking sections  11 . The interlinking sections  11  allow the contact surface  13  to change to allow the contact surface  13  to become longer laterally and move rearward when the seat back structure  1  is occupied (loaded) by a user of the seat system  1 . This provides a sink in feel when the user sits in the seat back structure  5 . 
         [0057]      FIG. 2  is a partial rear view of the seat system  1 . The seat back structure  5  is shown in an unoccupied position A and an occupied position B. In position A, the contact surface  13  has a first length  15 . In position B, the contact surface  13  has a second length  17 . The second length  17  of the contact surface  13  is greater than the first length  15  of the contact surface  13 . The rate (resistance) for the seat back structure  1  to go from position A to position B can be brought about by the material of the seat back structure  5  itself or from an additional support member. Loading for the seat back structure  5  or the support member is centered on a lumbar area  19 . If the support member is not used, cutouts (not shown) may be made in the corrugated surface  7  to reduce stress on the seat back structure  5  and to focus loading in the lumber area  19 . The cutouts in the corrugated surface  7  may also be applied if the support member is used. 
         [0058]      FIG. 3  is a partial perspective view of the seat system  1 . The seat back structure  5  may include no foam. In another embodiment, the seat back structure  5  may be formed with a limited amount of foam. The seat back structure  5  may be formed of thermoplastic polyurethane or another semi-compliant material. The panel may also be made from a thermoplastic elastomer that allows the corrugations to recoil to their original state and resist loading thereby creating a predefined suspension rate. This allows the panel to become not only a supporting surface but also a suspension member. The corrugated surface  7  may be formed in the seat back structure  5  by injection molding or by any other suitable process. 
         [0059]      FIG. 4  is an enlarged view of the seat system  1  in a lower area of the seat frame  3 . The seat frame  3  has a connecting member  21 . The connecting member  21  is connected to a first seat frame portion  23  and a second seat frame portion  25 . The seat back structure  5  includes a seat back structure portion  27 . The seat back structure portion  27  is attached to the seat frame  3  at the back of the seat frame  3 . It is understood that other portions of the seat back structure  5  can be connected to the seat frame  3  in a similar manner. This improves trim out and allows a lower area of the seat back structure  5  to deflect with a perpendicular load applied to the seat back structure  5  by the user. 
         [0060]      FIG. 5  is a perspective view of the seat system  1 . The seat back structure  5  has a first side bolster  29  and a second side bolster  31 . A stiffness (compliance ratio) of the first side bolster  29  and the second side bolster  31  can be tuned to meet a rate determined most beneficial to an occupant. 
         [0061]      FIG. 6  is a partial sectional view of the seat back structure  1 . Each interlinking section  11  is located at a position that is below a position of each vertically oriented member  9 . Each interlinking section  11  extends in an area between two vertically oriented members  9 . The seat back structure  5  is able to stretch in a lateral direction  33  based on one or more of the material thickness of the seat back structure  5 , material properties of the seat back structure  5 , the depth c of the interlinking sections  11  and localized cutouts in the corrugated surface  7 . The depth c is defined as the distance between a location of one of the interlinking sections  11  and a location of one of the vertically oriented member  9 . When the seat back structure  5  is stretched (the seat back structure  5  stretches in an accordion-like manner when occupied by a user), a distance increases between each vertically oriented member  9  and another one of the vertically oriented members  9 . Alterations to these sections can alter the stiffness of the panel and the rate at which it resists change. The addition of local changes can change the rate locally to tune the resistance as it rises up the back. 
         [0062]      FIG. 7  is a partial perspective view of the seat system  1 . The seat back structure  5  interacts at one or more locations  35 ,  37 ,  39 ,  41 ,  43 ,  45  with the seat frame  3 . The locations  35 ,  37 ,  39 ,  41 ,  43 ,  45  are offset from the contact surface  13 . This allows deflection of the contact surface  13  such that no area of the contact surface  13  is restricted from deflection, which is of particular importance in a shoulder region  47  of the seat back structure  5 . If designed for manufacture by injection molding ribs may be used to allow deflection thereby creating an energy management system. 
         [0063]      FIG. 8  is a perspective view of the seat system  1 . By changing section properties of the seat back structure  5  at locations where the seat back structure  5  is connected to the seat frame  3 , a stiffness of the bolsters  29 ,  31  can be altered. A stiffness (compliance ratio) of the first side bolster  29  and the second side bolster  31  is determined based on the section properties of stiffening members going inward or outward from corresponding affixing points shown horizontally. The shape and location of the stiffening members can be tuned to meet a rate determined most beneficial to an end consumer. Construction can be ribs, beads or any means known to create a stiffening and distributing section. A constant stiffness may be provided along an edge of the bolsters  29 ,  31 . 
         [0064]      FIG. 9  is another perspective view of the seat system  1 . A headrest structure  55  is connected to the seat frame  3 . Printing circuitry is connected to the seat back structure  5 . The printing circuitry may provided over the seat back structure  5 . The seat back structure  5  may be formed of one sheet of polymer and the printing circuitry may be printed on the polymer. It is also possible that the seat back structure  5  is formed of two or more sheets of polymer and the printed circuitry may be provided on the two or more sheets of polymer. A heating element  49  is connected to the seat back structure  5 . A strain gage  51  is connected to the seat back structure  5 . Any number of heating elements and strain gages  51 ,  53  may be connected to the seat back structure  5 . The heating element  49  and the strain gage  51  may be printed on the seat back structure  5 . The seat back structure  5  may be provided with an electro active polymer. The electro active polymer provides the seat back structure  5  with haptic and massage features. The electro active polymer allows a user to become aware of a vehicle in a blind spot of a user&#39;s vehicle by providing stimulative feedback, such as a buzzing feature. The electro active polymer also allows for a driving stimulant to give feedback from an engine of the user&#39;s vehicle and/or driving dynamics. Though shown as preprocessed prior to forming, these additions could be adhered to the panel if injection molding or another process is involved. 
         [0065]      FIG. 10  is a rear perspective view of the seat system  1 . The seat system  1  includes a suspension structure  57 . The suspension structure  57  is connected to the seat frame  3 . The suspension structure  57  is arranged opposite a lumbar region  71  of the seat back structure  5 . The suspension structure  57  has a plurality of springs  59 , a plurality of vertically extending suspension members  61  and two wires  63 ,  65 . The springs  59  and the two wires  63 ,  65  may be made of steel. The vertically extending suspension members  61  may be made of a thermoplastic elastomer. It is also possible that the springs  59  may be formed of a thermoplastic elastomer. The wires  63 ,  65  are connected to the seat frame  3 . The wires  63 ,  65  and the springs  59  form a leaf spring system. Each spring  59  is provided between one of the vertically extending suspension members  61  and another one of the vertically extending suspension members  61 . A first mechanism  67  is associated with one of the wires  63  for adjusting a tension of the wire  63 . A second mechanism  69  is associated with another one of the wires  65  for adjusting a tension of the wire  65 . The first mechanism  67  and the second mechanism  69  are located on a side of the seat frame  3 . A deflection of the seat back structure  5  is varied based on the tension of the wires  63 ,  65 . Bending of the wires  63 ,  65  controls displacement of the vertically extending suspension members  61 . Bending of the wires  63 ,  65  also controls the deflection of the seat back structure  5 . In another embodiment, it is possible to use only one wire and one mechanism for adjusting the tension of the one wire. In another embodiment, it is possible incorporate the springs  59  and suspension members  61 , which form a basket, into the panel, which is beneficial if the panel is constructed from a thermoplastic elastomer. 
         [0066]      FIG. 11  is a top view of the seat system  1  prior to a user engaging the seat back structure  5 . The wire spring  63  extends from one side of the seat frame  3  to another side of the seat frame  3 . A stop element  74  is located on one side of the seat frame  3 . Another stop element  75  may be provided on another side of the seat frame  3 . As a user sits in the seat back structure  5 , the seat back structure  5  deflects and pushes the suspension structure  57  in a rearward direction until resistance in the suspension structure  57  reaches an equilibrium.  FIG. 12  is a top view of the seat system  1  after a user has engaged the seat back structure  5 . 
         [0067]      FIG. 13  is a perspective view of the suspension system  57 . Each spring  59  has a slot  77 . A first group of springs  59  are associated with the wire spring  63 . The wire spring  63  extends through the slot  77  of each spring  59  associated with the first group of springs  59 . A second group of springs  59  are associated with the wire spring  65 . The wire  65  extends through the slot  77  of each spring  59  associated with the second group of springs  59 . The first mechanism  67  and the second mechanism  69  are located laterally with respect to the suspension members  61 . Shown are two systems, but there could one or any plurality of systems. 
         [0068]      FIG. 14  is a partial perspective view of the first mechanism  67 . The second mechanism  69  is formed of the same components of the first mechanism  67  and is not discussed to avoid repetition. The first mechanism  67  includes a housing  79 . The housing  79  has a first opening  78  for receiving a connecting element for connecting the housing  79  to the seat frame  3 . The housing  79  has a surface  81  defining a plurality of threads  82  and a second opening  80 . A tension adjustment element  83  has a plurality of threads  85  that cooperate with the threads  82  to rotatably connect the tension adjustment element  83  to the housing  79 . The tension adjustment element  83  is arranged in the second opening  80  when the tension adjustment element  83  is fastened to the housing  79 . An element  87  is connected to one end of the wire spring  63 . By rotating the tension adjustment element  83  in a first direction, a distance the wire spring  63  must travel from bending to tension is reduced and a spring  89  and/or a stop compliant element  91  goes into compression. By rotating the tension adjustment element  83  in a second direction, which is opposite to the first direction, the distance the wire spring  63  must travel from bending to tension is increased and the spring  89  and/or the stop compliant element  91  goes into compression. The purpose of the adjustable system is to alter a profile of the seat shape along the spine. 
         [0069]      FIG. 15  is an enlarged view of the stop element  74  and the stop element  75 . In one embodiment, the stop element  74  and the stop element  75  include the spring  89 . In another embodiment, the stop element  74  and the stop element  75  include the stop compliant element  91 . The stop compliant element  91  may be formed of elastomer. In another embodiment, one of the stop elements includes the spring and another one of the stop elements includes the stop compliant member  91 . The purpose of these secondary compressive elements  89 ,  91  is to create a dual rate system so it does not abruptly come to a stop when an occupant overloads the seat system. 
         [0070]      FIG. 16  is a perspective view of the suspension system  57 . The wire  63  has compliant end stops  93 ,  95 , which include bent portions of the wire  63 . The wire  65  has compliant end stops  97 ,  99 , which include bent portions of the wire  65 . The compliant end stops  93 ,  95 ,  97 ,  99  allow for a secondary rate of deflection of the vertically oriented members  9 . In another embodiment, it is possible to integrate the vertically extending suspension members  61  in the seat back structure  5 . 
         [0071]      FIG. 17  is a top view of the seat system  1 . The wires  63 ,  65  span a distance D. The distance D is about 400 mm. The targeted sink in (the amount of deflection of the seat back structure in the rearward direction) of a user is 25-40 mm. The stop element  74  and/or the stop element  75  can be deflected by a distance E in a lateral direction, which allows the suspension system  57  to deflect in a rearward direction. The stop element  74  and the stop element  75  allow for the suspension system  57  to go into tension, which provides high strength capability for overload and abuse. A stop position of the suspension system  57  is provided by the stop element  74  and the stop element  75 . The stop position can be changed by the stop element  74  and the stop element  75 , which changes the contour of the seat back structure  5 . 
         [0072]      FIG. 18  shows a back panel  1 ′ developed for a composite frame structure  3 ′. Offset attachments  100 ′,  101 ′ to the frame  3 ′ allows a compressive deflection of bolsters  29 ′,  31 ′. Grooves  102 ′, 103 ′ provide the ability to package a fabric or leather trim seam common on seatback construction. This seam location allows trim deflection at a critical point on the seat without foam to compress. 
         [0073]      FIG. 19  is a cross section view of the composite frame structure  3 ′. The composite frame structure  3 ′ has a stop feature  104 ′,  105 ′ to limit deflection of bolsters  29 ′,  30 ′ to limit stress in the panel P. The suspension system is a series arrangement where spring members  106 ,  107  supplement resistance of the grooves  102 ′,  103 ′. The panel is affixed to the frame  3 ′ at locations  108 , 109 . 
         [0074]    While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.