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. The seat assemblies often include a recliner assembly pivotably coupling the seat back to the seat cushion. It is commonly known for the recliner assembly to prevent rotation of the seat back relative to the seat cushion when the recliner assembly is locked.

Further, the seat assemblies often include a remote handle assembly attached to the seat assembly and configured to selectively unlock the recliner assembly. It is commonly known for the remote handle assembly to include a handle rotatable by an occupant and configured to actuate the remote handle assembly to unlock the recliner assembly and allow the occupant to adjust the seat back position. In addition, it is commonly known for the remote handle assembly to be optionally actuated by a power actuator, such as when the seat assembly includes a fold flat feature.

However, in certain known remote handle assemblies, the handle attached to the remote handle assembly exhibits excessive lateral play that may be perceived as an indication of poor quality by the occupant. In addition, certain known remote handle assemblies include a box with a cover supporting and containing internal components of the remote handle assembly. The box, eover, and associated fasteners add cost and manufacturing process complexity to the remote handle assembly. <CIT> discloses a vehicle seat that can be individually adjusted by a single operating member. In the known vehicle seat, an operating lever and a pulley are normally linked via a switch member. The pulley is linked with a reclining mechanism and a sliding mechanism such that the respective mechanisms can be unlocked individually by operating the operating lever upward or downward.

It is desirable, therefore, to provide a remote handle assembly having reduced perceived lateral looseness when the handle is rotated by an occupant. It is also desirable to provide a remote handle assembly having less components so that the cost is reduced, and the manufacturing process is less complex.

According to one embodiment, there is provided a remote handle assembly for selectively unlocking a component in a seat assembly for an automotive vehicle. The remote handle assembly comprises a handle bracket having a hole extending laterally through the handle bracket, a pulley having a pivot hole extending axially through the pulley, a handle spline having a passageway extending axially through the handle spline, and a pin extending through the passageway in the handle spline, the pivot hole in the pulley, and the hole in the handle bracket, wherein the pulley is pivotably coupled to the pin between an unactuated position and an actuated position and the handle spline is pivotably coupled to the pin between an unactuated position and an actuated position and the pin is fixedly coupled to the handle bracket and is configured to retain the handle bracket, the pulley and the handle spline together.

According to another embodiment, there is provided a seat assembly for an automotive vehicle. The seat assembly comprises a seat cushion, a seat back pivotably coupled to the seat cushion, a recliner assembly configured to prevent rotation of the seat back relative to the seat cushion, and a remote handle assembly for selectively unlocking the recliner assembly. The remote handle assembly comprises a handle bracket having a hole extending laterally through the handle bracket, wherein the handle bracket is adapted to be mounted on the seat cushion, a pulley having a pivot hole extending axially through the pulley, a handle spline having a passageway extending axially through the handle spline, and a pin extending through the passageway in the handle spline, the pivot hole in the pulley, and the hole in the handle bracket, wherein the pulley is pivotably coupled to the pin between an unactuated position and an actuated position and the handle spline is pivotably coupled to the pin between an unactuated position and an actuated position and the pin is fixedly coupled to the handle bracket and is configured to retain the handle bracket, the pulley and the handle spline together.

<FIG> illustrate components of 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> pivotably coupled to a seat cushion <NUM> by inboard and outboard recliner assemblies <NUM>. The recliner assemblies <NUM> are configured to prevent rotation of the seat back <NUM> relative to the seat cushion <NUM> while the recliner assemblies <NUM> are locked. The recliner assemblies <NUM> are selectively unlocked by actuating release levers <NUM> operatively coupled to the respective recliner assemblies <NUM>.

The seat assembly <NUM> includes a remote handle assembly <NUM> configured to actuate the release levers <NUM> to remotely unlock the recliner assemblies <NUM>. A first embodiment of the remote handle assembly <NUM> is shown in <FIG>. The remote handle assembly <NUM> includes a handle spline <NUM>, a pulley <NUM> and a handle bracket <NUM>. The pulley <NUM> is pivotably coupled with both the handle spline <NUM> and the handle bracket <NUM>.

Referring to <FIG>, the handle spline <NUM> includes a generally cylindrical section <NUM> having an external spline <NUM> and a passageway <NUM> extending longitudinally through the cylindrical section <NUM>. As depicted in <FIG>, the passageway <NUM> is butterfly-shaped in cross-section having opposing side portions <NUM>, <NUM>. As shown in <FIG>, a rim <NUM> extends circumferentially around a proximal end of the cylindrical section <NUM> of the handle spline <NUM>, forming a cavity <NUM>. As depicted in <FIG>, a spring slot <NUM> extends radially through the rim <NUM>, and an actuator tab <NUM> projects radially from the rim <NUM>. The actuator tab <NUM> includes a cam surface <NUM>, the purpose of which is further described below. In one embodiment, the handle spline <NUM> is formed out of a zinc alloy such as Zinc Alloy <NUM> (ASTM AC41A), as a non-limiting example.

Referring to <FIG>, the pulley <NUM> includes a hub <NUM> and a sector <NUM> projecting radially from the hub <NUM>. A pivot hole <NUM> extends axially through the hub <NUM> and defines an axis of rotation of the pulley <NUM>. Opposing primary cable channels <NUM> extend circumferentially along an outer portion of the sector <NUM> and terminate in a retention hole <NUM> passing axially through the sector <NUM>. A passageway <NUM> extends between each cable channel <NUM> and each retention hole <NUM>. As best shown in <FIG>, a secondary cable channel <NUM> extends circumferentially along the outer portion of the sector <NUM> and terminates at an end wall <NUM> having a cable hole <NUM> extending circumferentially therethrough. As depicted in <FIG>, the pulley <NUM> includes a ledge <NUM> projecting from a distal surface <NUM> of the pulley <NUM>. The ledge <NUM> is configured to frictionally engage with the cam surface <NUM> on the actuator tab <NUM>, as shown in <FIG>. In one embodiment, the pulley <NUM> is formed out of a plastic such as nylon <NUM>/<NUM>, as a non-limiting example.

Referring to <FIG>, the handle bracket <NUM> includes a keyed hole <NUM>, a spring hole <NUM>, and opposing attachment slots <NUM>, <NUM> extending laterally through the handle bracket <NUM>. In the embodiment shown in <FIG>, the keyed hole <NUM> has a double d-shape. The handle bracket <NUM> is formed from steel as a non-limiting example.

Referring to <FIG> and <FIG>, the remote handle assembly <NUM> also includes a pin <NUM> configured to retain the components of the remote handle assembly <NUM> together. The pin <NUM> includes a central section <NUM> extending from a head <NUM>. As shown in <FIG>, the central section <NUM> has a double d-shape in cross-section with generally parallel side walls <NUM> extending between curved end walls <NUM>. The central section <NUM> is sized and shaped such that it will pass through and be pivotably coupled to the passageway <NUM> in the handle spline <NUM> while the head <NUM> is sized and shaped such that it will not pass through the passageway <NUM> in the handle spline <NUM>. Shown in <FIG>, a ledge <NUM> on the proximal end of the head <NUM> extends radially from the central section <NUM>.

Shown in <FIG>, a generally cylindrical section <NUM> projects axially away from the central section <NUM> of the pin <NUM>. The cylindrical section <NUM> is sized and shaped such that it will pass through and be pivotably coupled to the pivot hole <NUM> in the hub <NUM> of the pulley <NUM>. A stop ledge <NUM> on the proximal end of the central section <NUM> extends radially from the cylindrical section <NUM>. Projecting axially from the cylindrical section <NUM> and forming a proximal end of the pin <NUM> is an end section <NUM>. A base ledge <NUM> on the proximal end of the cylindrical section <NUM> projects radially from the end section <NUM>.

As shown in <FIG>, the end section <NUM> of the pin <NUM> and the keyed hole <NUM> in the handle bracket <NUM> are sized and shaped such that the end section <NUM> will pass through the keyed hole <NUM> in the handle bracket <NUM>, but will not rotate within the keyed hole <NUM>. In an exemplary embodiment shown in <FIG>, the end section <NUM> of the pin <NUM> and the keyed hole <NUM> in the handle bracket <NUM> have a double d-shape, as a non-limiting example. The pin <NUM> is formed out of a carbon steel, such as SAE J403 grade <NUM>, as a non-limiting example.

As best shown in <FIG>, the remote handle assembly <NUM> also includes a pulley spring <NUM>, such as a torsion spring, a coiled spring, or the like. The pulley spring <NUM> is operatively coupled between the pulley <NUM> and the handle bracket <NUM>, and applies a bias force to the pulley <NUM> urging the pulley <NUM> to rotate in the clockwise direction (arrow <NUM>) as viewed in <FIG>. The pulley spring <NUM> is formed out of music wire such as ASTM A228, as a non-limiting example.

Referring to <FIG> and <FIG>, the remote handle assembly <NUM> also includes a spline spring <NUM>, such as a coil spring, a torsion spring, or the like. In one embodiment, the spline spring <NUM> is formed out of music wire such as ASTM A228, as a non-limiting example. The spline spring <NUM> is operatively coupled between the handle spline <NUM> and the pin <NUM> with the spline spring <NUM> applying a bias force to the handle spine <NUM> urging the handle spline <NUM> to rotate in the clockwise direction (arrow <NUM>) as viewed in <FIG>. It will be appreciated that the spring geometry of the spline spring <NUM> and the pulley spring <NUM> may be adjusted to meet torque requirements of different seat assemblies <NUM>.

As depicted in <FIG> and <FIG>, the remote handle assembly <NUM> also includes a manual cable attachment <NUM> and a power cable attachment <NUM>. The manual and power cable attachments <NUM>, <NUM> have respective base portions <NUM>, <NUM> configured to fixedly couple the cable attachments <NUM>, <NUM> to the respective attachment slot <NUM>, <NUM> in the handle bracket <NUM>. The manual cable attachment <NUM> includes a pair of holes <NUM>, and the power cable attachment <NUM> includes a cable hole <NUM>. In one exemplary embodiment, the manual and power cable attachments <NUM>, <NUM> are formed out of a plastic such as nylon <NUM>/<NUM>, as a non-limiting example.

<FIG> illustrate an assembly method of the remote handle assembly <NUM> according to one embodiment of the present invention. Referring to <FIG>, the handle spline <NUM> is slid onto the pin <NUM> (arrow <NUM>) until the distal end of the handle spline <NUM> abuts the ledge <NUM> on the head <NUM> of the pin <NUM>. Next, the spline spring <NUM> is inserted into the cavity <NUM> (arrow <NUM>) in the handle spline <NUM> with the inner end <NUM> of the spline spring <NUM> wrapped around the central section <NUM> of the pin <NUM> and the outer end <NUM> of the spline spring <NUM> passing through the spring slot <NUM> in the handle spline <NUM> as reflected in <FIG>. Referring back to <FIG>, next, the pulley <NUM> is slid onto the pin <NUM> through the pivot hole <NUM> (arrow <NUM>) until the stop ledge <NUM> on the pin <NUM> abuts a distal surface <NUM> of the hub <NUM> of the pulley <NUM>, as shown in <FIG>. At this point, the rim <NUM> of the handle spline <NUM> abuts the distal surface <NUM> of the hub <NUM> of the pulley <NUM>.

Next, the pulley spring <NUM> is assembled onto the pulley <NUM> (arrow <NUM>). As shown in <FIG>, a second end <NUM> of the pulley spring <NUM> is frictionally engaged with a side portion <NUM> of the pulley <NUM>, and a first end <NUM> of the pulley spring <NUM> is inserted through the spring hole <NUM> in the handle bracket <NUM> (arrow <NUM>). The end section <NUM> of the pin <NUM> is then aligned with and inserted into the keyed hole <NUM> in the handle bracket <NUM>, as shown by arrow <NUM> so that the base ledge <NUM> on the pin <NUM> frictionally engages with a distal surface <NUM> of the handle bracket <NUM>, as depicted in <FIG>.

<FIG> shows the end section <NUM> of the pin <NUM> protruding from the rear side of the handle bracket <NUM>. Next, the end section <NUM> of the pin <NUM> is riveted flush to the handle bracket <NUM>, shown as element <NUM> in <FIG>. Alternatively, the end section <NUM> may be staked against the handle bracket <NUM>. The pin <NUM> is shown in <FIG> after the riveting process and removed from the remote handle assembly <NUM>. Referring to <FIG> and <FIG>, the lateral looseness of the handle spline <NUM> is controlled by the riveting or staking process in combination with the ledges <NUM>, <NUM>, <NUM> on the pin <NUM> that define internal hard stops. Depicted in <FIG>, after the pin <NUM> is riveted or staked against the handle bracket <NUM>, the base portions <NUM>, <NUM> of the manual and power cable attachments <NUM>, <NUM> are fixedly coupled to the respective attachment slot <NUM>, <NUM> in the handle bracket <NUM> (arrow <NUM>, <NUM>).

Referring to <FIG>, primary Bowden cables <NUM>, <NUM>' operatively couple the remote handle assembly <NUM> to the respective release levers <NUM>. The proximal ends of the primary Bowden cables <NUM>, <NUM>' are inserted through the respective cable holes <NUM> in the manual cable attachment <NUM> and extend through the respective cable channels <NUM> and the passageways <NUM> in the pulley <NUM> and terminate in the retention holes <NUM>. Each primary Bowden cable <NUM>, <NUM>' passes longitudinally through a conduit <NUM> having a distal end fixedly coupled to the seat assembly <NUM> by a fitting attachment <NUM> and a proximal end fixedly coupled to the manual cable attachment <NUM>, as best illustrated in <FIG>.

The seat assembly <NUM> also includes a power actuator <NUM> operatively coupled to the remote handle assembly <NUM> via a secondary Bowden cable <NUM>. The power actuator <NUM> applies tension to the secondary Bowden cable <NUM> while the power actuator <NUM> is actuated. The tension is removed from the secondary Bowden cable <NUM> when the power actuator <NUM> is deactivated.

A proximal end <NUM> of the secondary Bowden cable <NUM> is inserted through the cable hole <NUM> in the power cable attachment <NUM> through the secondary cable channel <NUM> and the cable hole <NUM> in the pulley <NUM>, and terminates with an end fitting <NUM>. The secondary Bowden cable <NUM> passes longitudinally through a secondary conduit <NUM>, which is fixedly coupled to the power cable attachment <NUM>.

The seat assembly <NUM> also includes a recliner handle <NUM> positioned for easy access by the occupant and operatively coupled to the remote handle assembly <NUM>, as illustrated in <FIG>. The recliner handle <NUM> is rotatable between an unactuated position (shown as recliner handle <NUM>) and an actuated position (shown as recliner handle <NUM>'). The recliner handle <NUM> is spring-biased towards the unactuated position.

The recliner handle <NUM> has an internal spline configured to matingly engage with the external spline <NUM> on the handle spline <NUM>. As depicted in <FIG>, the opposing side portions <NUM>, <NUM> in the passageway <NUM> in the handle spline <NUM> define the unactuated position and the actuated position, respectively, of both the handle spline <NUM> and the recliner handle <NUM>. The side portions <NUM>, <NUM> of the passageway <NUM> may be adjusted for the travel range required for a specific recliner handle <NUM>.

To unlock the recliner assemblies <NUM>, the occupant rotates the recliner handle <NUM> about the pin <NUM> from the unactuated position to the actuated position, shown as element <NUM>' in <FIG>. Rotating the recliner handle <NUM> to the actuated position <NUM>' causes the actuator tab <NUM> of the handle spline <NUM> to rotate about the pin <NUM> in the counterclockwise direction (arrow <NUM>') as viewed in <FIG> to a tab actuated position (shown as actuator tab <NUM>'). The engagement between the cam surface <NUM> of the actuator tab <NUM> and the ledge <NUM> on the pulley <NUM> causes the pulley <NUM> to rotate about the pin <NUM> in the counterclockwise direction (arrow <NUM>') to the sector actuated position (shown as sector <NUM>' in <FIG>). The rotation of the sector <NUM> to the sector actuated position <NUM>' applies tension to the primary Bowden cables <NUM>, <NUM>', which actuates the release levers <NUM> to unlock the recliner assemblies <NUM>. The occupant may pivot the seat back <NUM> relative to the seat cushion <NUM> while the occupant retains the recliner handle <NUM> in the actuated position <NUM>' and the recliner assemblies <NUM> are unlocked.

After the occupant releases the recliner handle <NUM>, the spline spring <NUM> rotates the actuator tab <NUM> of the handle spline <NUM> about the pin <NUM> in the clockwise direction (arrow <NUM>) as viewed in <FIG> from the tab actuated position <NUM>' to the tab unactuated position <NUM>, which returns the recliner handle <NUM> to the unactuated position. In addition, the pulley spring <NUM> rotates the sector <NUM> in the clockwise direction (arrow <NUM>) about the pin <NUM> from the sector actuated position <NUM>' to the sector unactuated position <NUM> since the load applied by the actuator tab <NUM> onto the pulley <NUM> has been removed. When the sector <NUM> is returned to the sector unactuated position <NUM>, tension is removed from the primary Bowden cables <NUM>, <NUM>', which removes the tension applied the to the release levers <NUM> causing the recliner assemblies <NUM> to automatically relock.

Referring to <FIG> and <FIG>, when the occupant initiates a fold flat function, the power actuator <NUM> applies tension to the secondary Bowden cable <NUM> causing the sector <NUM> to rotate about the pin <NUM> in the counterclockwise direction (arrow <NUM>') to the sector actuated position <NUM>'. The rotation of the sector <NUM> to the sector actuated position <NUM>' applies tension to the primary Bowden cables <NUM>, <NUM>' thereby actuating the release levers <NUM> and causing the recliner assemblies <NUM> to unlock, at which point the seat back <NUM> may be rotated so that the seat back <NUM> overlays the seat cushion <NUM>. During the fold flat function, the recliner handle <NUM> is decoupled from the power actuator <NUM> so that the recliner handle <NUM> remains stationary while the power actuator <NUM> rotates the sector <NUM>. To relock the recliner assemblies <NUM>, the power actuator <NUM> removes tension from the secondary Bowden cable <NUM>, which allows the pulley spring <NUM> to rotate the sector <NUM> about the pin <NUM> in the clockwise direction (arrow <NUM>) towards the sector unactuated position <NUM>.

A second embodiment of the remote handle assembly <NUM>' is shown in <FIG>, where like primed reference numerals represent similar elements as those described above. Only significant differences between the two embodiments are reflected in the Figures and the description below. In the second embodiment of the remote handle assembly <NUM>', the pin <NUM>' is fixedly coupled to the handle bracket <NUM>' by a bolt <NUM>. A threaded shaft <NUM> on the bolt <NUM> extends from a bolt head <NUM> and is configured to meshingly engage with a threaded hole <NUM> extending axially in the proximal end of the pin <NUM>'. The remote handle assembly <NUM>' is shown fully assembled in <FIG> with the bolt head <NUM> abutting the rear side of the handle bracket <NUM>'.

A third embodiment of the remote handle assembly <NUM>" is shown in <FIG>, where like double primed reference numerals represent similar elements as those described above. Only significant differences between the embodiments are reflected in the Figures and the description below. In the third embodiment, a pin <NUM>" is inserted through the keyed hole <NUM>" in the handle bracket <NUM>" and fastened to the handle spline <NUM> by a bolt <NUM>.

Referring to <FIG>, the pin <NUM>" has a keyed shaft <NUM> projecting from a stepped flange <NUM>. The stepped flange <NUM> includes a first ledge <NUM> offset from a second ledge <NUM>. The keyed shaft <NUM> has a double d-shape in cross-section. The keyed hole <NUM>" in the handle bracket <NUM>" is sized and shaped such that the second ledge <NUM> will enter the keyed hole <NUM>". A threaded hole <NUM> extends axially into the distal end of the pin <NUM>". A threaded shaft <NUM> on the bolt <NUM> extends from a bolt head <NUM> and is configured to matingly engage with the threaded hole <NUM> in the pin <NUM>".

The remote handle assembly <NUM>" is assembled by inserting the distal end of the pin <NUM>" into the keyed hole <NUM>" in the rear side of the handle bracket <NUM>". Next, the components of the remote handle assembly <NUM>" are mounted in reverse order onto the pin <NUM>", and the threaded shaft <NUM> of the bolt <NUM> is inserted into the passageway <NUM> in the distal end of the handle spline <NUM> and into the threaded hole <NUM> in the pin <NUM>". The fully assembled remote handle assembly <NUM>" is shown in <FIG> and <FIG>.

As discussed above, the seat assembly <NUM> of the present invention includes a remote handle assembly <NUM>, <NUM>', <NUM>". The remote handle assembly <NUM>, <NUM>', <NUM>" includes a pin <NUM>, <NUM>', <NUM>" passing axially through a handle spline <NUM> and fixedly coupled to a handle bracket <NUM>, <NUM>', <NUM>". The stepped pin <NUM>, <NUM>', <NUM>" has internal hard stops <NUM>, <NUM>, <NUM> that control the lateral looseness of the handle spline <NUM>. In addition, the remote handle assembly <NUM>, <NUM>', <NUM>" lacks a box, a cover, and fasteners fixedly coupling the cover to the box. The reduction of components in the remote handle assembly <NUM>, <NUM>', <NUM>" reduces the component cost and reduces manufacturing process complexity.

Claim 1:
A remote handle assembly (<NUM>; <NUM>') for selectively unlocking a component (<NUM>) in a seat assembly (<NUM>) for an automotive vehicle, the remote handle assembly (<NUM>; <NUM>') comprising:
a handle bracket (<NUM>; <NUM>') having a hole (<NUM>; <NUM>') extending laterally through the handle bracket (<NUM>; <NUM>');
a pulley (<NUM>) having a pivot hole (<NUM>) extending axially through the pulley (<NUM>);
a handle spline (<NUM>) having a passageway (<NUM>) extending axially through the handle spline (<NUM>); and
a pin (<NUM>; <NUM>') extending through the passageway (<NUM>) in the handle spline (<NUM>), the pivot hole (<NUM>) in the pulley (<NUM>), and the hole (<NUM>; <NUM>') in the handle bracket (<NUM>; <NUM>'), wherein the pulley (<NUM>) is pivotably coupled to the pin (<NUM>; <NUM>') between an unactuated position and an actuated position and the handle spline (<NUM>) is pivotably coupled to the pin (<NUM>; <NUM>') between an unactuated position and an actuated position and the pin (<NUM>; <NUM>') is fixedly coupled to the handle bracket (<NUM>; <NUM>') and is configured to retain the handle bracket (<NUM>; <NUM>'), the pulley (<NUM>) and the handle spline (<NUM>) together,
wherein the passageway (<NUM>) in the handle spline (<NUM>) is butterfly-shaped in cross-section and a portion of the pin (<NUM>; <NUM>') in the passageway (<NUM>) has a double d-shape in cross section.