Patent Description:
Automotive vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above a vehicle floor. In sedan type or other vehicles, rear seating assemblies are often fixedly secured to the vehicle floor and have limited adjustability due to the limited space within the rear compartment of the vehicle. It is common for these rear seat assemblies to include a seat back coupled to a seat cushion by a pivot assembly for providing selective pivotal folding of the seat back relative to the seat cushion between a use position and a fold flat position overlying the seat cushion to provide additional storage space within the vehicle rear compartment. It is also common to include a recliner assembly operatively coupled between the seat back and the seat cushion to provide selective pivotal adjustment of the seat back between the use position and a rearward reclined position to provide seat occupant comfort. Alternatively, vehicle rear seat assemblies are also known that have a seat back secured to a fixed striker on the vehicle by a high latch. The high latch is selectively decoupled from the fixed striker allowing the seat back tobe rotated from an upright position towards a folded position. Certain known seat assemblies are selectively moveable between a use position and a reclined slouch position while the high latch is engaged with the fixed striker.

However, in a sedan type vehicle, space behind the rear seat assembly is typically limited, or not available, to allow sufficient clearance for rearward pivoting and reclining of the seat back relative to the seat cushion. Further, the range of motion of the seat back is limited by the high latch coupled to the fixed striker.

<CIT> discloses a seat assembly for an automotive vehicle comprises a seat cushion and a seat back pivotally coupled to the seat cushion for movement between a use position and a fold flat position overlying the seat cushion. A seat track assembly is coupled to the seat cushion for providing selective adjustment of the seat assembly between an upright design position and a reclined slouch position wherein the seat back is automatically pivoted rearwardly in response to forward sliding movement of the seat cushion. A sliding fold flat latch mechanism is operatively coupled to the seat back for slidably guiding the seat back during movement of the seat assembly between the upright design position and the reclined slouch position and for actuation between a locked condition retaining the seat back in the use position and an unlocked condition allowing pivotal movement of the seat back to the fold flat position.

<CIT> discloses an adjustment unit for a vehicle seat in a vehicle is disclosed. Said adjustment unit comprises a longitudinal adjustment mechanism for adjusting the vehicle seat along a direction of travel of the vehicle, said longitudinal adjustment mechanism comprising a first rocker that is mounted in such a way as to be rotatable about a transverse direction extending perpendicular to the direction of travel of the vehicle.

According to the invention, a seat assembly for use in an automotive vehicle with the features of claim <NUM> is provided. The invention further provides a high latch for use in s seat assembly with the features of claim <NUM>.

<FIG> illustrate a seat assembly <NUM> for use in an automotive vehicle according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

As depicted in <FIG>, the seat assembly <NUM> includes a seat back <NUM>, a seat cushion <NUM>, a seat base <NUM>, and a pair of fore/aft adjusters <NUM>. <FIG> illustrates the seat assembly <NUM> in a full reclined position. The seat back <NUM> is rotatably coupled to the seat cushion <NUM> by opposing free pivots <NUM>. The seat assembly <NUM> includes a seat back spring <NUM> operatively coupled between the seat back <NUM> and the seat cushion <NUM> to rotationally biases the seat back <NUM> in a forward direction (arrow <NUM>) around the free pivots <NUM>. The seat cushion <NUM> is coupled to the seat base <NUM> which is fixedly secured to the fore/aft adjusters <NUM>. A towel bar <NUM> is operatively coupled to the fore/aft adjusters <NUM> and configured to release a locking mechanism to allow the seat base <NUM> to be transposable fore and aft along the fore/aft adjusters <NUM>.

Referring to <FIG>, the seat assembly <NUM> also includes a striker bar <NUM> attached to a support wall <NUM> behind the seat back <NUM>. The striker bar <NUM> is generally U-shaped and includes a vertically elongated striker portion <NUM> extending between an upper end <NUM> and a lower end <NUM>. The upper and lower ends <NUM>, <NUM> extend in a generally horizontal direction with distal ends fixedly coupled to the support wall <NUM>. It should be appreciated that the shape and structure of the striker bar <NUM> can vary without departing from the scope of the present invention.

Referring to <FIG>, the seat assembly <NUM> further includes a high latch <NUM> that is pivotably coupled to the seat back <NUM> and configured to selectively couple to the striker bar <NUM>. Referring to <FIG> and <FIG>, the high latch <NUM> includes a disc recliner <NUM> mounted to a recliner A-bracket <NUM> and a recliner B-bracket <NUM> to allow the recliner A-bracket <NUM> to rotate relative to the recliner B-bracket <NUM>. The disc recliner <NUM> includes a guide plate <NUM>, a tooth plate <NUM>, a cam <NUM>, a recliner shaft <NUM>, recliner pawls (not shown), a recliner release lever <NUM> and a recliner spring <NUM>. The guide plate <NUM> is rotatably coupled to the tooth plate <NUM>, the cam <NUM> is operatively coupled to the recliner pawls, and the recliner pawls (not shown) are operatively coupled to both the guide plate <NUM> and the tooth plate <NUM>. The cam <NUM> rotates between a locked condition, where the recliner pawls (not shown) prevent the tooth plate <NUM> from rotating relative to the guide plate <NUM>, and an unlocked condition, where the recliner pawls (not shown) allow the guide plate <NUM> to rotate relative to the tooth plate <NUM>. Referring to <FIG>, the recliner shaft <NUM> is fixedly coupled to the cam <NUM> and fixedly coupled to the recliner release lever <NUM>. The recliner spring <NUM> is operatively coupled between the recliner shaft <NUM> and the guide plate <NUM> to bias the cam <NUM> towards the locked condition. Rotation of the recliner release lever <NUM> rotates the recliner shaft <NUM> to rotate the cam <NUM> into the unlocked condition. When the recliner release lever <NUM> is released, the recliner spring <NUM> forces the cam <NUM> back to the locked condition. An exemplary disc recliner <NUM> is further described in PCT publication <CIT>.

The guide plate <NUM> is mounted into a recliner hole <NUM> near a lower end of the recliner A-bracket <NUM>. Referring to <FIG>, the tooth plate <NUM> is mounted into a laterally-facing mounting hole <NUM> in the recliner B-bracket <NUM>, which is fixedly coupled to the seat back <NUM>. The recliner A-bracket <NUM> is rotatable relative to the recliner B-bracket <NUM> when the disc recliner <NUM> is in the unlocked condition. In contrast, the recliner A-bracket <NUM> is rotationally locked to the recliner B-bracket <NUM> when the disc recliner <NUM> is in the locked condition. Referring to <FIG>, a high latch assembly spring <NUM> is coupled between the recliner A-bracket <NUM> and the recliner B-bracket <NUM> to bias the recliner A-bracket <NUM> in a forward direction (arrow <NUM>).

The high latch <NUM> also includes a pivoting and sliding latch assembly <NUM> (hereinafter called "latch assembly") configured to latch and/or unlatch the high latch <NUM> from the striker bar <NUM>. As best shown in <FIG>, <FIG>, and <FIG>, the latch assembly <NUM> includes lower and upper support housings <NUM>, <NUM> that form inboard and outboard passages <NUM>, <NUM> on opposite sides of the lower and upper support housings <NUM>, <NUM>. Referring to <FIG>, the latch assembly <NUM> also includes a latch hook <NUM> pivotably coupled to the lower support housing <NUM> at pivot <NUM> to move between a sliding latched condition engaged with the striker bar <NUM> and an unlatched condition released from the striker bar <NUM>. The latch hook <NUM> includes a C-shaped slot <NUM> configured to matingly engage with the striker bar <NUM> when the latch assembly <NUM> is latched to the striker bar <NUM>. The latch hook <NUM> also includes a V-shaped notch having a stop surface <NUM> projecting at an angle from engagement surface <NUM>. A latch post <NUM> projects from a lower side of the latch hook <NUM> near the proximal end of the latch hook <NUM>. A latch spring <NUM> is operatively coupled between the lower support housing <NUM> and the latch post <NUM> to bias the latch hook <NUM> towards the unlatched condition (i.e., clockwise as viewed in <FIG>). It should be appreciated that the latch post <NUM> and latch spring <NUM> could be replaced with a conventional torsion spring without departing from the scope of the present invention.

Also shown in <FIG>, the latch assembly <NUM> includes a pawl <NUM> pivotally coupled to the lower support housing <NUM> at pivot <NUM> for releasable engagement with the latch hook <NUM> to maintain the latch hook <NUM> in the sliding latched condition. The pawl <NUM> has a locking surface <NUM> on a proximal end and a cam surface <NUM> projecting at an angle from the locking surface <NUM>. The locking and cam surfaces <NUM>, <NUM> are configured to matingly engage with the stop surface <NUM> and the engagement surface <NUM>, respectively, when the latch hook <NUM> is in the sliding latched condition and the pawl <NUM> is in a locked position shown in <FIG>. A pawl post <NUM> projects at generally a right angle from an upper surface of the pawl <NUM> near the proximal end of the pawl <NUM>. A pawl spring <NUM> (see <FIG>) is operatively coupled between the pawl post <NUM> and the upper support housing <NUM> to rotationally bias the pawl <NUM> relative to the pivot <NUM> in a counterclockwise direction as viewed in <FIG>. It should be appreciated that the pawl post <NUM> and pawl spring <NUM> could be replaced with a conventional torsion spring without departing from the scope of the present invention. A cable post <NUM> projects at generally a right angle from the upper surface of the pawl <NUM> near a distal end of the pawl <NUM>. As shown in <FIG>, the cable post <NUM> and the pawl post <NUM> may extend through openings in the upper support housing <NUM>.

A cable extends between the cable post <NUM> and a fold flat release handle located on a top end <NUM> (see <FIG>) of the seat back <NUM> for actuating and releasing the pawl <NUM> from locking engagement with the latch hook <NUM>. Actuating the fold flat release handle applies tension to the cable and causes the pawl <NUM> to rotate to an unlocked position (clockwise as viewed in <FIG>), which disengages the pawl locking surface <NUM> from the latch hook stop surface <NUM> and allows the latch spring <NUM> to rotate the latch hook <NUM> to the unlatched condition to decouple the latch assembly <NUM> from the striker bar <NUM>.

When tension is released from the cable, the pawl spring <NUM> causes the pawl <NUM> to rotate towards an engaged condition (counterclockwise) with the pawl cam surface <NUM> frictionally engaged with the latch hook engagement surface <NUM>. However, the latch spring <NUM> retains the latch hook <NUM> in the unlatched condition while the C-shaped slot <NUM> is disengaged from the striker bar <NUM>. When the striker bar <NUM> is brought into contact with the C-shaped slot <NUM>, the striker bar <NUM> applies a load onto the latch hook <NUM> causing the latch hook <NUM> to rotate in the counterclockwise direction as viewed in <FIG>. As the latch hook <NUM> rotates in the counterclockwise direction, frictional contact between the engagement surface <NUM> and the cam surface <NUM> causes the pawl <NUM> to rotate in the clockwise direction until the locking surface <NUM> frictionally engages with the stop surface <NUM>. The pawl <NUM> wedges the latch hook <NUM> in the sliding latched condition with the striker bar <NUM>.

Referring to <FIG>, the high latch <NUM> includes a latch mounting bracket <NUM>, a latch support strap <NUM>, an inboard latch pivot <NUM> and an outboard latch pivot <NUM> to mount the latch assembly <NUM> to the recliner A-bracket <NUM>. The latch mounting bracket <NUM> includes a central portion <NUM> extending between an upper tab <NUM> and a lower tab <NUM>. A pivot hole <NUM> extends laterally through the upper tab <NUM>, and a pair of mounting holes <NUM> extends laterally through the lower tab <NUM>. The latch support strap <NUM> is a generally U-shaped bracket having a cross member <NUM> extending between inboard and outboard tabs <NUM>, <NUM>. Inboard and outboard pivot holes <NUM>, <NUM> extend laterally through the inboard and outboard tabs <NUM>, <NUM>, respectively. As best shown in <FIG>, the cross member <NUM> includes a C-shaped slot <NUM> providing clearance for the striker bar <NUM>. The upper support housing <NUM> is omitted in <FIG> for illustrative purposes.

The inboard latch pivot <NUM> extends through the inboard pivot hole <NUM> in the inboard tab <NUM> of the latch support strap <NUM>, through the pivot hole <NUM> in the upper tab <NUM> of the latch mounting bracket <NUM>, and into the inboard passage <NUM> in the latch assembly <NUM>. The outboard latch pivot <NUM> extends through the outboard pivot hole <NUM> of the latch support strap <NUM>, through a pivot hole <NUM> near an upper end of the recliner A-bracket <NUM>, and into the outboard passage <NUM> in the latch assembly <NUM>.

The mounting holes <NUM> in the lower tab <NUM> of the latch mounting bracket <NUM> are aligned with a pair of mounting holes <NUM> spaced between the pivot hole <NUM> and the recliner hole <NUM> in the recliner A-bracket <NUM>. The latch mounting bracket <NUM> is fixedly coupled to the recliner A-bracket <NUM> by mechanical fasteners inserted through the mounting holes <NUM>, <NUM>.

The seat assembly <NUM> can be repositioned upon demand by the occupant between upright positions including the full recline position (<FIG> and <FIG>), a forward comfort position (<FIG> and <FIG>), and a reclined slouch position (<FIG>) by adjusting the high latch <NUM> while the latch assembly <NUM> is slidably latched to the striker bar <NUM>. In addition, the seat assembly <NUM> can be repositioned upon demand by the occupant from any one of the upright positions to a fold flat position (<FIG>) when the high latch <NUM> is decoupled from the striker bar <NUM>. Further, the seat assembly <NUM> can be repositioned upon demand by the occupant from the fold flat position to the full recline position.

Referring to <FIG>, the seat back <NUM> is initially in the full recline position with the recliner A-bracket <NUM> in the upright rotational position, the disc recliner <NUM> in the locked condition, the recliner release lever <NUM> unactuated, and the fore/aft adjusters <NUM> in the locked condition. The latch assembly <NUM> is in the sliding latched condition with an upper portion of the striker bar <NUM>. In addition, the latch assembly <NUM> is pivotably coupled to the recliner A-bracket <NUM> (arrow <NUM>) through the latch pivots <NUM>, <NUM>. The disc recliner <NUM> locks the rotation of the recliner A-bracket <NUM> relative to the seat back <NUM> while the disc recliner <NUM> is in the locked condition. Also, the high latch assembly spring <NUM> spring-biases the recliner A-bracket <NUM> in the forward direction (arrow <NUM>) towards the upright rotational position. The seat back <NUM> is spring-biased forward (arrow <NUM>) relative to the free pivots <NUM> towards the forward comfort position by the seat back spring <NUM>. Forward rotation of the seat back <NUM> is restricted by the high latch <NUM> since the latch assembly <NUM> is coupled to the striker bar <NUM> and the disc recliner <NUM> is in the locked condition.

Referring to <FIG> and <FIG>, to move the seat assembly <NUM> from the full recline position to the forward comfort position, the occupant adjusts the high latch <NUM> by actuating an adjustment lever (not shown) operatively coupled to the recliner release lever <NUM>. The actuation of the adjustment lever causes the recliner release lever <NUM> to rotate the cam <NUM> to the unlocked condition which unlocks the disc recliner <NUM>. The recliner A-bracket <NUM> is free to rotate relative to the seat back <NUM> (arrow <NUM>, <NUM>') while the disc recliner <NUM> is unlocked. Depicted in <FIG>, the forward biasing force (arrow <NUM>) of the seat back spring <NUM> rotates the seat back <NUM> forward (arrow <NUM>) about the free pivots <NUM> after the disc recliner <NUM> is in the unlocked condition. The seat back spring force (arrow <NUM>) overcomes the forward-biasing force (arrow <NUM>) of the recliner spring <NUM>, causing the recliner A-bracket <NUM> to rotate rearward (arrow <NUM>) and the latch assembly <NUM> to slide downward (arrow <NUM>) along the striker bar <NUM> during forward adjustment of the seat back <NUM>. The latch assembly <NUM> is pivotably coupled to the recliner A-bracket <NUM> (arrow <NUM>) to ensure that the latch assembly <NUM> slides down the striker bar <NUM> during forward adjustment of the seat back <NUM>. The occupant may selectively position the seat back <NUM> at any angle between the full recline position and the forward comfort position. The occupant releases the adjustment lever when the seat back <NUM> is in the desired position, causing the disc recliner <NUM> to lock the recliner A-bracket <NUM> relative to the seat back <NUM>.

Referring to <FIG>, to move the seat assembly <NUM> from the forward comfort position to the full recline position, the occupant actuates the adjustment lever causing the recliner release lever <NUM> to rotate the cam <NUM> to the unlocked condition which unlocks the disc recliner <NUM>. Next, the occupant applies rearward loading (arrow <NUM>) on the seat back <NUM> while the adjustment lever is actuated and the disc recliner <NUM> is unlocked. The occupant may apply rearward loading (arrow <NUM>) onto the seat back <NUM> using the occupant's torso or hand, as nonlimiting examples. The rearward loading (arrow <NUM>) overcomes the forward-biasing force (arrow <NUM>) of the seat back spring <NUM> and rotates the seat back <NUM> rearward (arrow <NUM>') about the free pivots <NUM>.

The forward-biasing force (arrow <NUM>) of the high latch assembly spring <NUM> in combination with the latch assembly <NUM> being pivotably coupled (arrow <NUM>) to the recliner A-bracket <NUM> allows the latch assembly <NUM> to slide upward (arrow <NUM>') along the striker bar <NUM> without binding as the recliner A-bracket <NUM> rotates forward (arrow <NUM>') towards the upright rotational position. The rearward rotation (arrow <NUM>') of the seat back <NUM> returns the seat assembly <NUM> to the full recline position. The rearward rotation (arrow <NUM>') of the seat back <NUM> is limited by a hard stop on the recliner A-bracket <NUM> and/or the seat back <NUM>. After the seat back <NUM> is in the full upright position, the occupant releases the adjustment lever repositioning the disc recliner <NUM> to the locked condition.

Referring to <FIG>, to move the seat assembly <NUM> from the full recline position to the reclined slouch position, the occupant pulls up on the towel bar <NUM> (arrow <NUM>) unlocking the fore/aft adjusters <NUM>. While the fore/aft adjusters <NUM> are unlocked, the occupant slides the seat cushion <NUM> forward (arrow <NUM>) along the fore/aft adjusters <NUM> to the desired position. The seat back <NUM> and the recliner A-bracket <NUM> remain fixed relative to each other while the seat cushion <NUM> is being slid forward. The latch assembly <NUM> slides down the striker bar <NUM> (arrow <NUM>) allowing the seat back <NUM> to rotate rearward (arrow <NUM>') about the free pivots <NUM> in response to the seat cushion <NUM> sliding forward (arrow <NUM>). The latch assembly <NUM> pivots relative to the recliner A-bracket <NUM> as the latch assembly <NUM> slides down the striker bar <NUM> to prevent binding during forward adjustment (arrow <NUM>) of the seat cushion <NUM>. When the seat cushion <NUM> is in the desired position, the occupant releases the towel bar <NUM> to relock the fore/aft adjusters <NUM>. The occupant may selectively position the seat back <NUM> at any angle between the full recline position and the reclined slouch position.

To return the seat assembly <NUM> to the full recline position from the reclined slouch position, the occupant pulls the towel bar <NUM> upward (arrow <NUM>) causing the fore/aft adjusters <NUM> to be unlocked. Next, the occupant slides the seat cushion <NUM> rearward (arrow <NUM>'). The rearward motion (arrow <NUM>') of the seat cushion <NUM> in combination with the forward-biasing force (arrow <NUM>) of the seat back spring <NUM> causes the latch assembly <NUM> to slide upward (arrow <NUM>') along the striker bar <NUM> and rotates the seat back <NUM> in the forward direction (arrow <NUM>) about the free pivots <NUM>. The latch assembly <NUM> pivots as the latch assembly <NUM> slides along the striker bar <NUM> to prevent binding of the latch assembly <NUM> with the striker bar <NUM> as the seat back <NUM> rotates. The occupant releases the towel bar <NUM> locking the fore/aft adjusters <NUM> in place when the seat assembly <NUM> is in the desired position.

Referring to <FIG>, to move the seat assembly <NUM> from one of the upright positions to the fold flat position, the occupant actuates the fold flat release handle (not shown) causing the latch hook <NUM> to rotate away from the striker bar <NUM> unlocking the latch assembly <NUM> from the striker bar <NUM>. The forward biasing force (arrow <NUM>) of the seat back spring <NUM> begins to rotate the seat back <NUM> forward (arrow <NUM>) about the free pivots <NUM> after the latch assembly <NUM> is unlocked from the striker. If the fold-flat function is initiated from the forward comfort position or incremental positions between the full recline and forward comfort positions where the recliner A-bracket <NUM> is not in the upright rotational position, the disc recliner <NUM> automatically unlocks when the seat back <NUM> is rotated forward beyond a preset seat back angle (e.g., angle <NUM>). The forward-biasing force (arrow <NUM>) of the high latch assembly spring <NUM> then causes the recliner A-bracket <NUM> to rotate in the forward direction (arrow <NUM>') to the upright rotational position. The seat back <NUM> rotates forward until the seat back <NUM> overlays the seat cushion <NUM>. The rotation of the recliner A-bracket <NUM> to the upright rotational position assures that the seat assembly <NUM> is below a flat load floor line <NUM> when the seat back <NUM> is rotated to overlay the seat cushion <NUM>.

To return the seat assembly <NUM> to the full recline position from the fold flat position, the occupant rotates the seat back <NUM> rearward (arrow <NUM>') about the free pivots <NUM>. The disc recliner <NUM> is automatically relocked when the seat back <NUM> is rotated rearward (arrow <NUM>') past the exemplary preset seat back angle <NUM>. When the latch hook <NUM> of the latch assembly <NUM> is brought into contact with the striker bar <NUM>, additional rearward load (arrow <NUM> shown in <FIG>) applied to the seat back <NUM> causes the latch hook <NUM> to rotate in the counterclockwise direction (<FIG>) until the latch hook <NUM> is in the sliding latched condition with the striker bar <NUM>.

As discussed above, the seat assembly <NUM> of the present invention includes a high latch <NUM> having a pivoting and sliding latch assembly <NUM> and a disc recliner <NUM>. The seat assembly <NUM> is repositionable between the full recline, forward comfort, and recline slouch positions while the high latch <NUM> is coupled to the striker bar <NUM>. Further, the high latch <NUM> can be decoupled from the striker bar <NUM> allowing the seat assembly <NUM> to be repositioned from any of the upright positions to a fold flat position.

Claim 1:
A seat assembly (<NUM>) for use in an automotive vehicle, the seat assembly (<NUM>) comprising:
a seat cushion (<NUM>) adapted to be coupled to a floor of the vehicle;
a seat back (<NUM>) pivotably coupled to the seat cushion (<NUM>) ;
a striker bar (<NUM>) adapted to be fixedly secured to a support wall (<NUM>) in the vehicle;
a recliner bracket (<NUM>, <NUM>) pivotally coupled to the seat back (<NUM>); and
a latch assembly (<NUM>) pivotally coupled to the recliner bracket (<NUM>, <NUM>) and slidably coupled to the striker bar (<NUM>), wherein pivotal movement of the recliner bracket (<NUM>, <NUM>) relative to the seat back (<NUM>) causes the latch assembly (<NUM>) to slide along the striker bar (<NUM>) and the seat back (<NUM>) to pivot relative to the seat cushion (<NUM>) between a full recline position and a forward comfort position.