Patent Description:
<CIT> discloses a child restraint which includes a juvenile vehicle seat and an energy-absorption apparatus coupled to the juvenile vehicle seat. The energy-absorption apparatus is configured to absorb external energy associated with an external impact force applied to the energy-absorption apparatus.

One aspect of the present invention is directed to a child conveyance device comprising an impact energy absorbing apparatus disposed on a portion of the child conveyance device. In one embodiment, the impact energy absorbing apparatus includes an inner support configured to be positioned against the portion of the child conveyance device, the inner support having a receptacle formed therein, an outer cover configured to releasably secure the inner support, and an insert received within the receptacle of the inner support. The insert is held in place by the outer cover when securing the outer cover.

The insert has a wall with a closed end and an open end. The insert is sized to fit within the receptacle of the inner support with the closed end first entering the receptacle. In embodiments of the child conveyance device, the receptacle of the inner support may have a shape complimentary to a shape of the insert. The insert may embody a rectangular-shaped frustum. The insert may be configured to partially enter the receptacle of the inner support, with an internal volume being defined between the internal surfaces of the inner support and the outer surfaces of the insert. When an impact force having an amplitude less than a threshold value is applied to the impact energy absorbing apparatus, the insert may be configured to resist the impact force, and when an impact force having an amplitude greater than the threshold value is applied to the impact energy absorbing apparatus, the insert may be configured to slide inwardly into the receptacle of the inner support to absorb the impact force, with the insert being configured to occupy the internal volume of the receptacle as the insert moves into the receptacle. The insert may be caused to plastically deform as the insert is moved within the receptacle. The inner support may be secured to a shell of the safety seat by the outer cover. The shell of the safety seat holds the outer periphery of the outer cover in place. The child conveyance device further may include an inner cover configured to fit within an opening formed in the outer cover, with the inner cover shielding the insert when assembled. The inner cover may be designed to fit within an opening formed in the outer cover. The child conveyance device may be a child vehicle safety seat. An impact force applied to the impact energy absorbing apparatus may have an amplitude less than a threshold value causes the insert to resist the impact force. An impact force applied to the impact energy absorbing apparatus may have an amplitude greater than the threshold value causes the insert to slide inwardly into the receptacle of the inner support to plastically deform the insert. The impact energy absorbing apparatus may be replaceably secured to the portion of the child conveyance device. The inner support may be fabricated from foam material and the outer cover is fabricated from plastic material.

Another aspect of the present invention not covered by the scope of the appended claims is directed to an impact energy absorbing apparatus disposed on a portion of a child conveyance device. In one embodiment, the impact energy absorbing apparatus includes an inner support configured to be secured to the portion of the child conveyance device, the inner support having a receptacle formed therein, an outer cover configured to releasably secure the inner support, and an insert received within the receptacle of the inner support. The insert is held in place by the outer cover when securing the outer cover.

The insert includes a wall with a closed end and an open end in embodiments of the impact energy absorbing apparatus. The insert
may be sized to fit within the receptacle of the inner support with the closed end first entering the receptacle. The receptacle of the inner support may have a shape complimentary to a shape of the insert. The insert may embody a rectangular-shaped frustum. The insert may be configured to partially enter the receptacle of the inner support, with an internal volume being defined between the internal surfaces of the inner support and the outer surfaces of the insert. When an impact force having an amplitude less than a threshold value is applied to the impact energy absorbing apparatus, the insert may be configured to resist the impact force, and when an impact force having an amplitude greater than the threshold value is applied to the impact energy absorbing apparatus, the insert may be configured to slide inwardly into the receptacle of the inner support to absorb the impact force, with the insert being configured to occupy the internal volume of the receptacle as the insert moves into the receptacle. The insert may be caused to plastically deform as the insert is moved within the receptacle. The impact energy absorbing apparatus further may include an inner cover configured to fit within an opening formed in the outer cover, the inner cover shielding the insert when assembled. The inner cover may be designed to fit within an opening formed in the outer cover. The inner support may be fabricated from foam material and the outer cover is fabricated from plastic material.

Conventional seat belt systems in most motor vehicles are typically not appropriate for properly restraining infants or small children. Accordingly, parents or caregivers of infants or small children often transport the infants or small children in a child carrier commonly referred as a car seat or child vehicle safety seat when travelling in a motor vehicle, the use of which is required by law for children below a certain age in many jurisdictions. The car seat may be secured to the back seat of a motor vehicle with a seat belt, for example, a three-point safety belt and/or other connectors such as Isofix connectors. The car seat may be padded with different forms of energy absorbing materials, which may reduce forces that a child riding in the car seat may be exposed to during a motor vehicle collision. Conventional child vehicle safety seats have proven highly effective in reducing injuries to children which may otherwise have been sustained as a result of a motor vehicle collision. It has been recognized, however, that the side impact protection offered by many conventional child vehicle safety seats may be inadequate or at least may be improved upon. Regulations setting forth standards for side impact protection in child vehicle safety seats have recently been enacted in Europe and similar regulations are expected to be enacted in the United States of America. Provision of adequate levels of side impact protection in child vehicle safety seats to meet such regulations has thus become of increasing importance.

Aspects and embodiments disclosed herein include apparatus that may be coupled to conventional child vehicle safety seats and modifications to conventional child vehicle safety seats that may improve the side impact protection offered by the child vehicle safety seats. Some aspects and embodiments disclosed herein include an energy absorbing apparatus that may be mechanically coupled or formed integral with a portion of a side of a child vehicle safety seat and that may reduce side impact forces that a child occupying the child vehicle safety seat may be exposed to during a motor vehicle collision. Some embodiments of the apparatus may include a pair of interlocking shell elements and an energy absorbing material disposed within a cavity defined by the interlocking shell elements. The interlocking shell elements may be free to move relative to one another, for example, for one of the shell elements to slide into the other shell element, to reduce the size of the internal cavity upon application of an external force. Reduction of the size of the internal cavity may cause the energy absorbing material to mechanically compress and/or plastically deform or rupture and absorb forces which otherwise might be transferred to a child occupying the child vehicle safety seat. The energy absorbing apparatus may be reusable or, in some embodiments, may provide an indication that it should be replaced after absorbing a sufficiently high amount of energy.

One embodiment of a child vehicle safety seat is illustrated in elevational view from the side generally at <NUM> in <FIG>. The child vehicle safety seat <NUM> may be a stand-alone device or may be configured to be secured to, for example, a stroller frame or to a separate car seat base by the provision of appropriate securing mechanisms as are known in the art on, for example, a lower surface of the seat. The child vehicle safety seat <NUM> includes a shell <NUM> and a carrying handle <NUM> pivotally attached to the shell <NUM> at handle pivot mechanisms <NUM> which may be positioned on an outer surface of either or both sides of the shell <NUM>. The handle <NUM> is generally U-shaped, and may be pivoted into a position extending generally vertically upward from the pivot mechanism(s), into a position against a surface of the shell <NUM>, or into one or more intermediate positions. The shape, form, and method of connection of the handle <NUM> to the shell <NUM> is not, however, limited to that illustrated. Other handles having different shapes, orientations, or methods of connection to the shell of a child vehicle safety seat <NUM> may be utilized in various embodiments.

In some embodiments of a child vehicle safety seat <NUM> the handle pivot mechanisms <NUM> may be positioned at locations more lateral than many, if not all, other portions of the child vehicle safety seat <NUM>. Accordingly, the handle pivot mechanisms <NUM> may provide surfaces upon which it may be desirable to dispose embodiments of a side impact energy absorbing apparatus. <FIG> illustrates a generalized embodiment of a side impact energy absorbing apparatus <NUM> coupled to an outside surface of a handle pivot mechanism <NUM> of an embodiment of a child vehicle safety seat <NUM>, only a portion of which is illustrated in <FIG> for clarity.

Another embodiment of a side impact energy absorbing apparatus <NUM> is illustrated coupled to the handle pivot mechanism <NUM> of another embodiment of a child vehicle safety seat <NUM> in <FIG>. The positions and coupling of seatbelt straps <NUM> that may be used to secure the child vehicle safety seat <NUM> to a motor vehicle seat <NUM> is also illustrated in <FIG>. In some embodiments, a side impact energy absorbing apparatus <NUM> is provided on both lateral sides of a child vehicle safety seat <NUM>, for example, as illustrated in <FIG> in which the child vehicle safety seat <NUM> is illustrated in a highly simplified manner. In embodiments in which only a single side impact energy absorbing apparatus <NUM> is provided on a child vehicle safety seat <NUM>, the child vehicle safety seat <NUM> should be positioned such that the side impact energy absorbing apparatus <NUM> faces a surface of the motor vehicle, for example, a door of the motor vehicle, that the child vehicle safety seat <NUM> is most likely to come into contact with upon the motor vehicle experiencing a side impact collision.

In some embodiments, the side impact energy absorbing apparatus <NUM> includes a pair of outer shells, an upper shell <NUM> and a lower shell <NUM>. As used herein, the lower shell <NUM> shall be considered the shell that contacts and is disposed on embodiments of a child vehicle safety seat <NUM>. The outer periphery of one of the upper shell <NUM> or the lower shell <NUM> may be sized and shaped to fit within an internal perimeter of the other of the upper shell <NUM> or the lower shell <NUM>. The one of the upper shell <NUM> or the lower shell <NUM> may have an outer surface sized and shaped to slideably engage the internal surface of the other of the upper shell <NUM> or the lower shell <NUM> such that the one of the upper shell <NUM> or the lower shell <NUM> may slide into or out from an internal volume of the other of the upper shell <NUM> or the lower shell <NUM>. Outer surfaces of one embodiment of a pair of upper and lower shells <NUM>, <NUM> is illustrated in <FIG>. Inner surfaces of one embodiment of a pair of upper and lower shells <NUM>, <NUM> is illustrated in <FIG>. The upper and lower shells <NUM>, <NUM> may have internal features such as an internally projecting frustoconical projection <NUM> in the upper shell <NUM> and a recess <NUM> in the lower shell <NUM>. The recess <NUM> in the lower shell <NUM> may have a shape complimentary to the frustoconical projection <NUM>. The internal features of the upper and lower shells <NUM>, <NUM> should not be considered limited to having the shapes illustrated in <FIG>. In other embodiments the projection <NUM> may have an alternative shape, for example, that of a rectangle, a hemisphere or portion thereof, or a flat topped pyramid or square frustum and the recess <NUM> may have a complimentary shape.

The lower shell <NUM> may have a diameter that provides for the lower shell <NUM> to be at least partially inserted into the upper shell <NUM>, for example, as illustrated in <FIG>. An internal volume <NUM> is defined between the internal surfaces of the upper shell <NUM> and the lower shell when the lower shell <NUM> is at least partially inserted into the upper shell <NUM>. This internal volume <NUM> may be at least partially, or substantially completely, filled with a resilient material <NUM>, for example, a foam material or a memory foam material, as illustrated in <FIG>. The resilient material <NUM> may be provided in the form of a disc as illustrated in <FIG> and may deform to conform to the shape of the internal volume <NUM> when the upper and lower shells <NUM>, <NUM> are joined around the resilient material. The resilient material <NUM> may be a polyurethane memory foam or any other suitable polymeric foam material.

One or more features may provide for the lower shell <NUM> to be retained within the upper shell <NUM>. The upper and lower shells <NUM>, <NUM> may include, for example, bayonet mounts or a ridge or ridges <NUM> in the lower shell <NUM> that fit or that can be rotated into position below a complimentary ridge or ridges <NUM> in the upper shell <NUM> as illustrated in <FIG> and <FIG>. Alternatively or additionally a clip or clips <NUM> and complimentary landing ridge or ridges <NUM> may be provided on the upper and lower shells <NUM>, <NUM>, for example, as illustrated in <FIG>.

The upper and lower shells <NUM>, <NUM> may be formed from a stiff material, for example, polypropylene or another engineering plastic and may have diameters or widths of about two inches (about five cm) and heights of about two inches (about five cm), although these materials and dimensions should be considered non-limiting examples only.

In the figures referenced above, the shell having the lesser diameter is designated as the lower shell <NUM> and the shell having the greater diameter is illustrated as the upper shell <NUM>, however, it should be appreciated that in other embodiments, the lower shell <NUM> may have a greater diameter or cross-sectional area than the upper shell <NUM>. Further, the shells should not be considered limited to being cylindrical. In other embodiments, the shells may have alternative cross sections, for example, triangular cross sections or rectangular cross sections. Additionally, in some embodiments, the shell with the lesser diameter or cross sectional area may include an internal protrusion such as the frustoconical projection <NUM> and the shell with the greater diameter or cross sectional area may include a recess, such as the recess <NUM> illustrated in <FIG>.

The lower shell <NUM> may be mechanically coupled to a portion of a side of the child vehicle safety seat <NUM>, for example, to a wall <NUM> of a handle pivot mechanism <NUM> of the child vehicle safety seat <NUM>. On or more apertures <NUM> may be provided in a lower wall of the lower shell <NUM>, one of which is illustrated in <FIG>, through which a fastener, for example, a screw or bolt may pass to engage with and couple the lower shell <NUM> to the wall <NUM> of the child vehicle safety seat <NUM>. <FIG> illustrates an embodiment of the lower shell <NUM> (internal features omitted for clarity) secured to a wall <NUM> of a child vehicle safety seat <NUM> by multiple bolts <NUM> passing through the lower wall <NUM> of the lower shell <NUM> and through the wall <NUM> of the child vehicle safety seat <NUM> and secured by nuts <NUM> on the opposite side of the wall <NUM> as the lower shell <NUM>. <FIG> illustrates an embodiment in which a portion of the outer wall <NUM> of the lower shell <NUM> is threaded and engages internal threads of a receptacle <NUM> extending from the wall <NUM> so that the lower shell <NUM> may screwed into the receptacle <NUM> and be retained against the wall <NUM>. In other embodiments, the lower shell <NUM> may be secured to the wall <NUM> of a child vehicle safety seat <NUM> either fixedly or removably by other fastening mechanisms known in the art, for example, an adhesive, one or more clips, a bayonet mount, hook and loop fasteners, etc. Any one or more of the above referenced fastening mechanisms may be utilized alone or in combination. The upper shell <NUM> may be mounted on the side of the lower shell <NUM> not secured to the wall <NUM> in a manner as described above.

In use, if an impact force is applied to the upper shell <NUM> of the side impact energy absorbing apparatus <NUM>, the upper shell <NUM> is pushed inward into the lower shell <NUM>. The internal volume <NUM> between the upper and lower shells <NUM>, <NUM> is reduced, and the resilient material <NUM> within the internal volume <NUM> is compressed. Initially, the resilient material <NUM> is elastically deformed and absorbs impact energy at a first rate, e.g., the upper shell <NUM> is pushed inward toward the lower shell <NUM> at a first rate or distance per unit force. As additional force or impact energy is applied to the upper shell <NUM> of the side impact energy absorbing apparatus <NUM> the resilient material <NUM> is squeezed between the internal features of the upper and lower shells <NUM>, <NUM>, for example, the projection <NUM> and recess <NUM> to a degree that it begins to plastically deform or tear. This additional mechanism of deformation of the resilient material <NUM> causes the upper shell <NUM> to be pushed inward toward the lower shell <NUM> at a second rate or distance per unit force, which may be less than the first rate or distance per unit force and may absorb more impact energy than the elastic deformation of the resilient material <NUM>. In some embodiments, the additional mechanism of deformation of the resilient material <NUM> may begin after the upper and lower shells <NUM>, <NUM> are pushed together more than about <NUM>% of the distance of separation in their resting uncompressed state.

The side impact energy absorbing apparatus <NUM> may in some embodiments be reusable after absorbing impact energy. For example, if the absorbed impact energy is not sufficient to plastically deform the resilient material <NUM>, the resilient material <NUM> may return to its initial, pre-impact shape. In other embodiments, the energy absorbing apparatus <NUM> should be replaced after being subjected to a sufficiently high impact force. For example, if an impact force causes the resilient material <NUM> to plastically deform a user may observe that the upper and lower shells <NUM>, <NUM> do not return to their initial pre-impact configuration, which may provide an indication that the side impact energy absorbing apparatus <NUM>, or perhaps only the resilient material <NUM>, should be replaced. The fasteners or fastening mechanisms that hold the upper and lower shells <NUM>, <NUM> together, and/or the fasteners or fastening mechanisms that hold the lower shell <NUM> to a wall of the child vehicle safety seat <NUM> may be releasable such that the upper and lower shells <NUM>, <NUM> may be separated and the resilient material <NUM> replaced as needed or the side impact energy absorbing apparatus <NUM> may be removed and replaced as needed.

Referring to <FIG>, another embodiment of a side impact energy absorbing apparatus is generally indicated at <NUM>. In some embodiments, the side impact energy absorbing apparatus <NUM> is provided on both lateral sides of a child vehicle safety seat <NUM>. In embodiments in which only a single side impact energy absorbing apparatus <NUM> is provided on the child vehicle safety seat <NUM>, the child vehicle safety seat <NUM> should be positioned such that the side impact energy absorbing apparatus <NUM> faces a surface of the motor vehicle, for example, a door of the motor vehicle, that the child vehicle safety seat <NUM> is most likely to come into contact with upon the motor vehicle experiencing a side impact collision.

Referring to <FIG>, in some embodiments, the side impact energy absorbing apparatus <NUM> includes a foam inner support <NUM> and a rubber outer cover <NUM> that fits over the inner support. In one embodiment, the inner support <NUM> is held in place or otherwise secured on a side of the shell <NUM> of the child vehicle safety seat <NUM>. The inner support <NUM> may be sized and formed to fit within a receptacle of the shell <NUM> of the safety seat <NUM>. In one embodiment, the inner support <NUM> is secured to the shell <NUM> of the safety seat <NUM> by the outer cover <NUM>. As shown, the inner support <NUM> includes a receptacle <NUM> formed therein, the purpose of which will be described below.

The side impact energy absorbing apparatus <NUM> further includes a plastic insert <NUM> that is received within the receptacle <NUM> of the inner support <NUM> and a plastic inner cover <NUM> that is secured in place between the inner support and the outer cover <NUM> when the outer cover is secured to the inner support. As shown, the insert <NUM> has a relatively thin wall with a closed end and an open end, and is sized to fit within the receptacle <NUM> of the inner support <NUM> with the closed end first entering the receptacle. In one embodiment, the receptacle <NUM> of the inner support <NUM> may have a shape complimentary to the rectangular-shaped frustum insert <NUM>. In other embodiments, the insert <NUM> may have an alternative shape, for example, that of a conical, a hemisphere or portion thereof, or a flat-topped pyramid or square frustum and the receptacle <NUM> may have a complimentary shape.

To assemble the side impact energy absorbing apparatus <NUM>, the inner support <NUM> is held in place by the shell <NUM> and surrounding seat side foam of the safety seat <NUM>. In other embodiments, the inner support <NUM> can be held in place by glue, rivets, tape, or the like. The insert <NUM> is received within the receptacle <NUM> of the inner support with the inner cover <NUM> being placed over the open end of the insert. The outer cover <NUM> is placed over the inner cover <NUM>, and, in one embodiment, is secured to the inner cover <NUM>, for example, by a snap-fit connection associated with respective peripheries of the inner cover <NUM> and the outer cover <NUM> and/or the shell <NUM> of the safety seat <NUM>. In a certain embodiment, the shell <NUM> of the safety seat <NUM> holds the outer periphery of the outer cover <NUM> in place. In other embodiments, the outer cover <NUM> may be secured to the inner support <NUM> and/or the shell <NUM> of the safety seat <NUM> by mechanical fasteners.

Thus, it should be observed that the inner support <NUM> floats unattached to the shell <NUM> and/or the other components of the side impact energy absorbing apparatus <NUM>, but is held in place. In one embodiment, slots formed on the back of the inner support <NUM> are provided to clear ribs formed in the shell <NUM> so that the inner support <NUM> can engage a larger surface of the shell <NUM>. The ribs also prevent relative movement of the inner support <NUM> and the shell <NUM>. In some embodiments, the outer cover <NUM> is secured to the shell by any suitable method, such as heat staking of molded-in posts provided on the shell over holes formed in a flange of the outer cover.

Referring to <FIG> and <FIG>, the insert <NUM> is configured to partially enter the receptacle <NUM> of the inner support <NUM>. An internal volume <NUM> (<FIG>) is defined between the internal surfaces of the inner support <NUM> and the outer surfaces of the insert <NUM>. In some embodiments, the internal volume <NUM> may be an open space. In other embodiments, the internal volume may be at least partially, or substantially completely, filled with a resilient material, for example, a foam material or a memory foam material. The resilient material may be a polyurethane memory foam or any other suitable polymeric foam material.

The arrangement is such that an impact force applied to the impact energy absorbing apparatus <NUM> having an amplitude of less than a threshold value causes the insert <NUM> to resist the impact force. However, if the impact force applied to the impact energy absorbing apparatus <NUM> has an amplitude of greater than the threshold value, the insert <NUM> is configured to slide inwardly into the receptacle <NUM> of the inner support <NUM> to absorb the impact force. The insert <NUM> is configured to occupy the internal volume <NUM> of the receptacle <NUM> as the insert <NUM> moves into the receptacle <NUM>. In some embodiments, the insert <NUM> is caused to plastically deform as the insert is moved within the receptacle <NUM>.

The inner cover <NUM> is designed to fit within an opening <NUM> formed in the outer cover <NUM>. As shown, the inner cover <NUM> shields the insert <NUM> when assembled. However, the impact force applied to the impact energy absorbing apparatus <NUM> is applied from the inner cover <NUM> to the insert <NUM>, with the outer cover <NUM> being deformed. The inner cover <NUM> may include a logo or label formed on an outer surface.

As mentioned above, the inner support <NUM> may be fabricated from a foam material. The outer cover <NUM> may be fabricated from a flexible material, such as rubber. The insert <NUM> and the inner cover <NUM> each may be fabricated from a stiff material, for example, polypropylene or another engineering plastic, although these materials and dimensions should be considered non-limiting examples only.

As mentioned above, in one embodiment, the inner support <NUM> may be mechanically coupled to a portion of the side of the child vehicle safety seat <NUM>, for example, to the shell <NUM>.

The side impact energy absorbing apparatus <NUM> may in some embodiments be reusable after absorbing impact energy. In other embodiments, the energy absorbing apparatus <NUM> should be replaced after being subjected to a sufficiently high impact force.

Claim 1:
A child conveyance device (<NUM>) comprising:
an impact energy absorbing apparatus (<NUM>) disposed on a portion of the child conveyance device (<NUM>), the impact energy absorbing apparatus (<NUM>) including:
an inner support (<NUM>) configured to be positioned against the portion of the child conveyance device (<NUM>), the inner support (<NUM>) having a receptacle (<NUM>) formed therein;
an outer cover (<NUM>) configured to releasably secure the inner support (<NUM>); and
an insert (<NUM>) received within the receptacle (<NUM>) of the inner support (<NUM>), the insert (<NUM>) being held in place by the outer cover (<NUM>) when securing the outer cover (<NUM>), the insert (<NUM>) having a wall with a closed end and an open end, the insert (<NUM>) sized to fit within the receptacle (<NUM>) of the inner support (<NUM>) with the closed end first entering the receptacle (<NUM>).