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 inboard and outboard recliner mechanisms pivotably coupling the seat back to the seat cushion. It is commonly known for the recliner mechanisms to prevent rotation of the seat back relative to the seat cushion when the recliner mechanism is locked. The recliner mechanisms typically include an unlocking component, such as a recliner crank or a release lever, which is actuatable by a release cable.

Further, the seat assemblies often include a remote handle assembly configured to selectively unlock the recliner mechanism. It is commonly known for the remote handle assembly to include a handle pivotable by an occupant to unlock the recliner mechanisms so that the occupant may 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. A remote handle assembly operatively connected to a power actuator is commonly described as having a one touch feature (OTF). Non-OTF remote handle assemblies rely on manual operation of the handle to release the recliner mechanisms.

An exemplary non-OTF remote handle assembly, described in <CIT>, includes a pulley fixedly coupled to a handle spline and operatively coupled to a release cable. The pulley applies tension to the release cable in response to the occupant pivoting a handle attached to the handle spline to an actuated position. The recliner mechanisms are unlocked when tension is applied to the release cable. When the occupant releases the handle, a return spring rotates the pulley back to an unactuated position which allows the recliner mechanisms to be locked.

An exemplary OTF remote handle assembly, described in <CIT>, unlocks the recliner mechanisms with a power actuator and with a handle. The remote handle assembly includes a main pulley pivotally connected to the handle spline which is fixedly coupled to the handle. The handle spline includes a tab that travels in a slot in the main pulley so that the main pulley is selectively decoupled from the handle spline. Rotating the handle spline towards the actuated position causes the main pulley to pivot and apply tension to the release cable causing the recliner mechanisms to unlock. A second pulley is pivotally coupled to the main pulley and operatively coupled to an actuator cable connected to the power actuator. To automatically unlock the recliner mechanisms, the power actuator applies tension to the actuator cable causing the second pulley to pivot and engage with the main pulley and causes the main pulley to rotate towards the actuated position while the main pulley is decoupled from the handle spline. The handle remains stationary as the main pulley is rotated since the handle spline is decoupled from the main pulley.

However, decoupling the main pulley from the handle spline adds cost and manufacturing process complexity to the OTF remote handle assembly. In addition, it is common for remote handle assemblies to have unique components that are customized for each design application, such as for different seat assemblies or for different OTF and non-OTF versions.

It is desirable, therefore, to provide a remote handle assembly that includes common components for both the OTF and non-OTF versions. In addition, it is desirable to eliminate components that decouple the main pulley from the handle spline. 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. <CIT> discloses a release mechanism generates a force on a cable to operate an adjustment mechanism or the like in a seat or other device. The release mechanism includes a rotor, a housing, a spring, and a cover that attaches to the housing. The spring generates a torque permitting the rotor to form a temporary subassembly with the housing prior to final assembly. The spring also axially biases the rotor into engagement with the cover to prevent rattling.

According to the invention, a remote handle assembly with the features of claim <NUM> is provided.

<FIG> illustrate components of an automotive seat assembly <NUM> 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 mechanisms <NUM>. The recliner mechanisms <NUM> are configured to prevent rotation of the seat back <NUM> relative to the seat cushion <NUM> while the recliner mechanisms <NUM> are locked. The recliner mechanisms <NUM> are selectively unlocked by actuating release levers <NUM> operatively coupled to the respective recliner mechanisms <NUM>.

The seat assembly <NUM> includes a remote handle assembly <NUM> configured to actuate the release levers <NUM> to remotely unlock the recliner mechanisms <NUM>. A first embodiment of the remote handle assembly <NUM> is shown in <FIG>. Components of the remote handle assembly <NUM> are mounted between a rear housing <NUM> and a front housing <NUM>.

Referring to <FIG>, the rear housing <NUM> includes a base panel <NUM> extending between the opposing side walls <NUM>, <NUM>' and opposing end walls <NUM>, <NUM>'. Each end wall <NUM>, <NUM>' includes a U-shaped slot <NUM>, <NUM>'. Projecting generally perpendicularly from the base panel <NUM> is a generally cylindrical boss <NUM> having a passageway <NUM> extending longitudinally therethrough. A longitudinal axis of the boss <NUM> defines an axis of rotation <NUM>. The rear housing <NUM> includes spaced apart corner bosses <NUM> extending from the base panel <NUM>. A bore <NUM> extends longitudinally through each of the respective corner bosses <NUM>. In an exemplary embodiment, the bores <NUM> extend through the base panel <NUM>. Each corner boss <NUM> includes a side wall that defines a stop surface <NUM>. In addition, spaced apart ledges <NUM> extend generally perpendicularly from one side wall <NUM> and terminate in respective tabs <NUM> extending at an angle from the side wall <NUM>. In an exemplary embodiment, the side wall <NUM> adjacent the boss <NUM> includes an arcuate-shaped central segment <NUM> extending between opposing wing segments <NUM>, <NUM>'. The opposing wing segments <NUM>, <NUM>' are depicted as non-parallel, however, in alternate embodiments the opposing wing segments <NUM>, <NUM>' may be parallel to one another. Further, an arcuate-shaped notch <NUM> extends circumferentially along an upper edge of the central segment <NUM>. In addition, a plurality of triangular-shaped projections <NUM> having a catch surface <NUM> extend from opposing side walls <NUM>, <NUM>' of the rear housing <NUM>.

Referring to <FIG> and <FIG>, the front housing <NUM> includes a plurality of U-shaped tabs <NUM> extending at generally right angles from an outer surface <NUM> of the front housing <NUM>. A slot <NUM> in each of the U-shaped tabs <NUM> is configured to matingly engage with the catch surface <NUM> of the respective projections <NUM> on the rear housing <NUM> when the front housing <NUM> is assembled with the rear housing <NUM>, as shown in <FIG>. Extending through the front housing <NUM> are spaced apart mounting holes <NUM> and a centrally located spline hole <NUM>. The mounting holes <NUM> are generally aligned with the bores <NUM> in the rear housing <NUM> when the front housing <NUM> is assembled with the rear housing <NUM>.

As depicted in <FIG> and <FIG>, the remote handle assembly <NUM> also includes a power cable assembly <NUM> and a mechanism cable assembly <NUM>. The power cable assembly <NUM> includes an outer casing <NUM>, a power Bowden cable <NUM>, and a power cable attachment <NUM>. A proximal end of the outer casing <NUM> is fixedly coupled to the power cable attachment <NUM> which is fixedly coupled to one of the U-shaped slots <NUM>, <NUM>' in the rear housing <NUM>. The power Bowden cable <NUM> extends longitudinally through the outer casing <NUM>, through a passageway <NUM> (<FIG>) in the power cable attachment <NUM>, and into a cavity <NUM> in the rear housing <NUM>.

Referring to <FIG>, the mechanism cable assembly <NUM> includes inboard and outboard outer casings <NUM>, <NUM>', outboard and inboard Bowden cables <NUM>, <NUM>' (i.e., release Bowden cables), and a manual cable attachment <NUM>. Proximal ends of the outer casings <NUM>, <NUM>' are fixedly coupled to the manual cable attachment <NUM>, which is fixedly coupled to the other one of the U-shaped slots <NUM>, <NUM>' in the rear housing <NUM>. The Bowden cables <NUM>, <NUM>' extend longitudinally through the respective outer casings <NUM>, <NUM>', through respective passageways <NUM>, <NUM>' (<FIG>) in the manual cable attachment <NUM>, and into the cavity <NUM> in the rear housing <NUM>.

Referring to <FIG>, the remote handle assembly <NUM> also includes a spline shaft <NUM> pivotably coupled with the rear housing <NUM>. Referring to <FIG>, the spline shaft <NUM> includes a generally cylindrical section <NUM> having an external spline <NUM> and a passageway <NUM> extending longitudinally through the cylindrical section <NUM>. A sector <NUM> extends radially from a proximal end of the cylindrical section <NUM>. A pulley channel <NUM> (i.e., spline shaft pulley) extends circumferentially along an outer portion of the sector <NUM> between trailing and leading sides <NUM>, <NUM> of the sector <NUM>. Opposing attachment holes <NUM> extend axially through the sector <NUM> and adjoin the pulley channel <NUM>. Each attachment hole <NUM> includes a cable slot <NUM> extending generally radially outward to an exterior of the sector <NUM>. As best shown in <FIG>, an arm <NUM> projects radially from the sector <NUM> adjacent the cylindrical section <NUM> of the spline shaft <NUM>. The arm <NUM> is configured to fit within the notch <NUM> in the central segment <NUM> of the rear housing <NUM>, as shown in <FIG>. Depicted in <FIG>, a stop boss <NUM> projects from the trailing side <NUM> of the sector <NUM>. Referring to <FIG>, the leading side <NUM> defines a cam surface for the sector <NUM> and includes a second boss <NUM> spaced between side segments <NUM>, <NUM>. As depicted in <FIG>, the sector <NUM> also includes a generally U-shaped notch <NUM> extending between a recessed portion <NUM> of the sector <NUM> and a ledge <NUM>. The spline shaft <NUM> may have one or two pulley channels <NUM> without altering the scope of the present invention.

Referring to <FIG>, the remote handle assembly <NUM> also includes a one-touch feature (OTF) pulley <NUM> pivotably coupled with the rear housing <NUM>. Referring to <FIG>, the OTF pulley <NUM> includes a base <NUM> having generally a sector-shape and extending between trailing and leading sides <NUM>, <NUM>. The base <NUM> includes a spring notch <NUM>, as illustrated in <FIG>. In addition, a collar <NUM> projects generally perpendicular from a distal portion of the base <NUM> and terminates at a rim <NUM>. Further, a passageway <NUM> extends longitudinally through the collar <NUM> and the base <NUM>. The longitudinal axis of the collar <NUM> defines the axis of rotation <NUM> of the OTF pulley <NUM>.

Referring to <FIG>, the OTF pulley <NUM> includes a boss <NUM> having a generally cylindrical-shape and projecting from the base <NUM> and terminating at an upper surface <NUM>. An attachment aperture <NUM> extends longitudinally through the boss <NUM> and through a bottom surface <NUM> of the base <NUM>. The boss <NUM> also includes a lateral wall <NUM> and an end wall <NUM> extending downward from the upper surface <NUM>. In addition, the lateral wall <NUM> is sized and shaped to frictionally engage with the outer side segment <NUM> of the spline shaft <NUM> after assembly, as shown in <FIG>.

Shown in <FIG>, the OTF pulley <NUM> also includes an upper pulley channel <NUM> (i.e., a first mechanism pulley) that extends circumferentially from an opening in the lateral wall <NUM>, along the end wall <NUM> of the boss <NUM>, through the aperture <NUM> in the boss <NUM>, and terminates at another opening on the leading side <NUM>. The upper pulley channel <NUM> is sized and shaped to axially align with the pulley channel <NUM> in the spline shaft <NUM> when the OTF pulley <NUM> is assembled with the spline shaft <NUM>, as shown in <FIG>. When assembled, the upper pulley channel <NUM> and the pulley channel <NUM> form a single pulley channel.

Further, an upper slot <NUM> extends radially from the aperture <NUM> through the end wall <NUM> of the boss <NUM>, extends axially through the upper surface <NUM> of the boss <NUM>, and adjoins the upper pulley channel <NUM>. A portion of the aperture <NUM> adjacent the upper slot <NUM> defines an upper attachment location for one of the Bowden cables <NUM>, <NUM>' in the mechanism cable assembly <NUM> with the upper slot <NUM> allowing the Bowden cable <NUM>, <NUM>' to be inserted into the aperture <NUM> and along the upper pulley channel <NUM>.

Depicted in <FIG>, an outer wall <NUM> extends circumferentially along the base <NUM> between the cylindrical boss <NUM> and the trailing side <NUM> of the OTF pulley <NUM>. Referring to <FIG>, the OTF pulley <NUM> includes a lower pulley channel <NUM> (i.e., a second mechanism pulley) that extends circumferentially from an opening in the trailing side <NUM> along the outer wall <NUM>, through the aperture <NUM> in the boss <NUM>, and terminates at another opening on the leading side <NUM>. Further, a lower slot <NUM> extends radially from the aperture <NUM> through the outer wall <NUM>, extends axially through the bottom surface <NUM> of the base <NUM>, and adjoins the lower pulley channel <NUM>. A portion of the aperture <NUM> adjacent the lower slot <NUM> defines a lower attachment location for another one of the Bowden cables <NUM>, <NUM>' in the mechanism cable assembly <NUM> with the lower slot <NUM> allowing the Bowden cable <NUM>, <NUM>' to be inserted into the aperture <NUM> and along the lower pulley channel <NUM>.

As shown in <FIG>, the OTF pulley <NUM> includes a center pulley channel <NUM> (i.e., a power actuator pulley) that extends circumferentially from a cable opening <NUM> in the trailing side <NUM> along the outer wall <NUM>, through the aperture <NUM>, and terminates at a third opening on the leading side <NUM>. A narrow slot <NUM> extends between the center pulley channel <NUM> and through a wall portion <NUM> adjoining the trailing side <NUM> and the outer wall <NUM> of the OTF pulley <NUM>. The narrow slot <NUM> allows the power Bowden cable <NUM> to be inserted into the center pulley channel <NUM>. In addition, the center pulley channel <NUM> is spaced axially between the upper and lower pulley channels <NUM>, <NUM>.

Referring to <FIG>, a flange <NUM> extends from the boss <NUM> along the base <NUM> and generally towards the axis of rotation <NUM>. The flange <NUM> includes an intermediate wall <NUM> offset from a proximal wall <NUM>. The intermediate and proximal walls <NUM>, <NUM> form an engagement surface sized and shaped to frictionally engage with the second boss <NUM> and the inner side segment <NUM>, respectively, of the spline shaft <NUM> after assembly, as shown in <FIG>. In more detail, the lateral, intermediate, and proximal walls <NUM>, <NUM>, <NUM> define a pulley cam surface configured to frictionally engage with the sector cam surface formed by the second boss <NUM> spaced between side segments <NUM>, <NUM>.

As shown in <FIG>, the remote handle assembly <NUM> also includes a pulley spring <NUM>, a spline shaft spring <NUM>, and a pair of threaded insert/nuts <NUM>. The pulley spring <NUM> is a torsion spring having opposing spring legs <NUM>, <NUM> and a loop portion having an inner diameter larger than an outer diameter of the collar <NUM>. The spline shaft spring <NUM> is also a torsion spring having opposing spring legs <NUM>, <NUM> and a loop portion having an inner diameter larger than an outer diameter of the cylindrical section <NUM> of the spline shaft <NUM>. The threaded insert/nuts <NUM> have a proximal end sized and shaped to fit within respective bores <NUM> in the rear housing <NUM> and a distal end sized and shaped to fit within respective mounting holes <NUM> in the front housing <NUM>.

<FIG> illustrate an assembly method of the remote handle assembly <NUM> according to one embodiment of the present invention. Referring to <FIG>, the proximal ends of the threaded insert/nuts <NUM> are inserted into the respective bores <NUM> in the rear housing <NUM>. The OTF pulley <NUM> is slid onto the boss <NUM> in the rear housing <NUM> with the passageway <NUM> aligned with the boss <NUM> and the bottom surface <NUM> of the OTF pulley <NUM> facing the rear housing <NUM>. The pulley spring <NUM> is slid onto the OTF pulley <NUM> with the collar <NUM> extending through the loop portion of the pulley spring <NUM>. One spring leg <NUM> is inserted into the spring notch <NUM> in the OTF pulley <NUM>. The other spring leg <NUM> abuts the ledge <NUM> extending from the tab <NUM> in the rear housing <NUM>, as shown in <FIG>. Next, the spline shaft <NUM> is slid onto the boss <NUM> in the rear housing <NUM> with the boss <NUM> aligned with the passageway <NUM> in the spline shaft <NUM> and with the cylindrical section <NUM> oriented away from the OTF pulley <NUM>. Referring to <FIG>, the loop portion of the spline shaft spring <NUM> is slid over the cylindrical portion <NUM> of the spline shaft <NUM> and one of the spline spring legs <NUM> is inserted into the notch <NUM> in the spline shaft <NUM>. As illustrated in <FIG>, the other one of the spline spring legs <NUM> abuts the ledge <NUM> and the tab <NUM> in the rear housing <NUM>.

Referring to <FIG>, the pulley spring <NUM> is operatively coupled between the OTF pulley <NUM> and the rear housing <NUM>. The pulley spring <NUM> applies a bias force to the OTF pulley <NUM> urging the OTF pulley <NUM> to rotate in a clockwise direction as viewed in <FIG>. The pulley spring <NUM> causes the trailing side <NUM> of the OTF pulley <NUM> to frictionally engage with the stop surface <NUM> in the rear housing <NUM> when the OTF pulley <NUM> is unactuated. In addition, the spline shaft spring <NUM> is operatively coupled between the spline shaft <NUM> and the rear housing <NUM>. The spline shaft spring <NUM> applies a bias force to the spline shaft <NUM> urging the spline shaft <NUM> to rotate in the clockwise direction as viewed in <FIG>. The spline shaft spring <NUM> causes the stop boss <NUM> on the spline shaft <NUM> to frictionally engage with the stop surface <NUM> in the rear housing <NUM> when the spline shaft <NUM> is unactuated.

Also referring to <FIG>, after the spline shaft spring <NUM> is assembled with the spline shaft <NUM>, the power and manual cable attachments <NUM>, <NUM> are inserted into respective U-shaped slots <NUM>, <NUM>' in the rear housing <NUM>. A ball fitting <NUM> is fixedly coupled to a proximal end of the power Bowden cable <NUM>. Referring to <FIG>, the power Bowden cable <NUM> is inserted into the center pulley channel <NUM> and through the narrow slot <NUM> in the outer wall <NUM> of the OTF pulley <NUM> and through the opening in the trailing side <NUM> such that the ball fitting <NUM> abuts the trailing side <NUM>. The power Bowden cable <NUM> is slidably coupled to the center pulley channel <NUM>. In addition, the power Bowden cable <NUM> is retained within the center pulley channel <NUM> since the ball fitting <NUM> is larger than the opening in the trailing side <NUM>.

The outboard and inboard Bowden cables <NUM>, <NUM>' are terminated with respective crossbar stop sleeves <NUM>. The crossbar stop sleeve <NUM> attached to one of the Bowden cables <NUM>, <NUM>' is inserted into the upper attachment location in the aperture <NUM> of the OTF pulley <NUM> with the Bowden cable <NUM>, <NUM>' inserted through the upper slot <NUM> and into the upper pulley channel <NUM>. The Bowden cable <NUM>, <NUM>' is also inserted into the pulley channel <NUM> in the spline shaft <NUM>. In addition, the crossbar stop sleeve <NUM> attached to the other one of the Bowden cables <NUM>, <NUM>' is inserted into the lower attachment location in the aperture <NUM> with the Bowden cable <NUM>, <NUM>' inserted through the lower slot <NUM> and into the lower pulley channel <NUM> in the OTF pulley <NUM>. Referring to <FIG>, the front housing <NUM> is slid onto the spline shaft <NUM> with the cylindrical section <NUM> extending through the spline hole <NUM> in the front housing <NUM>. The front housing <NUM> is fixedly coupled to the rear housing <NUM> by snapping the U-shaped tabs <NUM> on the front housing <NUM> over the triangular shaped projections <NUM> on the rear housing <NUM>.

Referring to <FIG> and <FIG>, distal ends <NUM>, <NUM>' of the outboard and inboard Bowden cables <NUM>, <NUM>' are operatively coupled to the release lever <NUM> of respective recliner mechanisms <NUM>. The remote handle assembly <NUM> is configured to actuate the release levers <NUM> by applying tension to the outboard and inboard Bowden cables <NUM>, <NUM>' to remotely unlock the recliner mechanisms <NUM>.

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

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> has an internal spline configured to matingly engage with the external spline <NUM> on the spline shaft <NUM>. The recliner handle <NUM> is rotatable about the axis of rotation <NUM> of the spline shaft <NUM> between an unactuated position (shown as recliner handle <NUM>) and an actuated position (shown as recliner handle <NUM>'). The corresponding unactuated and actuated positions of the spline shaft <NUM> are shown in <FIG> and <FIG>, respectively. The recliner handle <NUM> is spring-biased towards the unactuated position by the spline shaft spring <NUM> operatively coupled between the spline shaft <NUM> and the rear housing <NUM>.

Referring to <FIG> and <FIG>, to unlock the recliner mechanisms <NUM>, the occupant rotates the recliner handle <NUM> about the axis of rotation <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 spline shaft <NUM> to rotate in the counterclockwise direction (arrow <NUM>) as viewed in <FIG>. The leading side <NUM> of the spline shaft <NUM> frictionally engages with the flange <NUM> on the OTF pulley <NUM>, causing the OTF pulley <NUM> to rotate in the counterclockwise direction (arrow <NUM>) with the spline shaft <NUM>. The spline shaft <NUM> and the OTF pulley <NUM> may be rotated in the counterclockwise direction (arrow <NUM>) until the leading side <NUM> of the flange <NUM> frictionally engages with one of the stop surfaces <NUM> in the rear housing <NUM>. Tension is applied to the outboard and inboard Bowden cables <NUM>, <NUM>' (arrow <NUM>) as the OTF pulley <NUM> rotates in the counterclockwise direction (arrow <NUM>). However, the counterclockwise rotation (arrow <NUM>) of the OTF pulley <NUM> does not apply tension to the power Bowden cable <NUM> since the power Bowden cable <NUM> can freely slide along the center pulley channel <NUM>. The recliner handle <NUM> allows the occupant to release the recliner mechanisms <NUM> via the upper and lower pulley channels <NUM>, <NUM> in the OTF pulley <NUM>.

The rotation of the OTF pulley <NUM> to the actuated position shown in <FIG> applies tension (arrow <NUM>) to the outboard and inboard Bowden cables <NUM>, <NUM>', which actuates the release levers <NUM> to unlock the recliner mechanisms <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 mechanisms <NUM> are unlocked.

After the occupant releases the recliner handle <NUM>, the spline shaft spring <NUM> rotates the spline shaft <NUM> about the axis of rotation <NUM> in a clockwise direction (arrow <NUM>' in <FIG>) from the actuated position (<FIG>) to the unactuated position (<FIG>), which returns the recliner handle <NUM> to the unactuated position (<FIG>). In addition, the pulley spring <NUM> rotates the OTF pulley <NUM> in the clockwise direction (arrow <NUM>') about the axis of rotation <NUM> from the actuated position (<FIG>) to the unactuated position (<FIG>) since the load applied by the spline shaft <NUM> onto the OTF pulley <NUM> has been removed. When the OTF pulley <NUM> is returned to the unactuated position (<FIG>), tension is removed from the outboard and inboard Bowden cables <NUM>, <NUM>', which removes the tension applied to the release levers <NUM> and causes the recliner mechanisms <NUM> to automatically relock.

Referring to <FIG>, when the occupant initiates a fold flat function, the power actuator <NUM> applies tension (arrow <NUM>) to the power Bowden cable <NUM> causing the OTF pulley <NUM> to rotate about the axis of rotation <NUM> in the counterclockwise direction (arrow <NUM>) from the unactuated position (<FIG>) to the actuated position (<FIG>). The rotation of the OTF pulley <NUM> to the actuated position (<FIG>) applies tension (arrow <NUM>) to the outboard and inboard Bowden cables <NUM>, <NUM>' thereby actuating the release levers <NUM> and causing the recliner mechanisms <NUM> to unlock. The seat back <NUM> may be rotated so that the seat back <NUM> overlays the seat cushion <NUM> while the recliner mechanisms <NUM> are unlocked. 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 OTF pulley <NUM>. The spline shaft <NUM> is decoupled from the OTF pulley <NUM> since the Bowden cable <NUM>, <NUM>' attached to the upper attachment location freely slides along the pulley channel <NUM> in the spline shaft <NUM> as the OTF pulley <NUM> is rotated.

To relock the recliner mechanisms <NUM>, the power actuator <NUM> removes tension from the power Bowden cable <NUM>, which allows the pulley spring <NUM> to rotate the OTF pulley <NUM> about the axis of rotation <NUM> in the clockwise direction (arrow <NUM>') towards the unactuated position (<FIG>). Tension is removed from the outboard and inboard Bowden cables <NUM>, <NUM>', which removes the tension applied to the release levers <NUM> and causes the recliner mechanisms <NUM> to automatically relock.

A second embodiment of the remote handle assembly <NUM>" is shown in <FIG>, where like double primed reference numerals represent similar elements as those described above. The second embodiment depicts a non-OTF version of the remote handle assembly <NUM>". 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 rear housing <NUM>" has a reduced depth in comparison to the rear housing <NUM> in the first embodiment. Referring to <FIG>, the outboard Bowden cable <NUM>" of the mechanism cable assembly <NUM>" extends longitudinally through the outer casing <NUM>", through the passageway <NUM>" in the manual cable attachment <NUM>", and into the rear housing <NUM>". Referring to <FIG>, after the threaded insert/nuts <NUM>, the spline shaft <NUM>, and the spline shaft spring <NUM> are assembled with the rear housing <NUM>", the crossbar stop sleeve <NUM>" is inserted into the attachment hole <NUM> on the spline shaft <NUM> and the outboard Bowden cable <NUM>" is inserted into the pulley channel <NUM>, as reflected in <FIG>, and the front housing <NUM> is attached to the rear housing <NUM>". It will be appreciated that one or more Bowden cables <NUM>" may be attached to the spline shaft <NUM> without altering the scope of the present invention.

The remote handle assembly <NUM>" is shown fully assembled in <FIG> with the spline shaft <NUM> in the unactuated position. Rotating the recliner handle <NUM> in the counterclockwise direction (arrow <NUM>) to the actuated position causes the spline shaft <NUM> to rotate to the actuated position shown in <FIG>. In the actuated position, the leading side <NUM> of the spline shaft <NUM> frictionally engages with the stop surface <NUM> in the rear housing <NUM>". Tension (arrow <NUM>) is applied to the outboard Bowden cable <NUM>" as the spline shaft <NUM> rotates towards the actuated position, causing the recliner mechanisms <NUM> to unlock. When the recliner handle <NUM> is released by the occupant, the spline shaft spring <NUM> automatically rotates the spline shaft <NUM> in the clockwise direction (arrow <NUM>') to the unactuated position (<FIG>). Tension is removed from the outboard Bowden cable <NUM>", which removes the tension applied to the release levers <NUM> and causes the recliner mechanisms <NUM> to automatically relock.

As discussed above, the remote handle assembly <NUM>, <NUM>" of the present invention includes common components in the OFT version and the non-OFT version with the rear housing <NUM>, <NUM>" adjusted in depth to accommodate the additional components in the OTF version. In addition, the spline shaft <NUM> is decoupled from the OTF pulley <NUM> while the power actuator <NUM> is applying tension to the power Bowden cable <NUM> without requiring additional decoupling components. The reduction in components in the remote handle assembly <NUM>, <NUM>" and the use of common parts between the OTF and non-OFT versions reduce component cost and reduce manufacturing process complexity.

Claim 1:
A remote handle assembly (<NUM>; <NUM>") for selectively unlocking a component in a seat assembly (<NUM>) for an automotive vehicle, the remote handle assembly (<NUM>; <NUM>") comprising:
a rear housing (<NUM>; <NUM>") having a boss (<NUM>; <NUM>");
a spline shaft (<NUM>) pivotally coupled to the boss (<NUM>; <NUM>") around an axis of rotation (<NUM>), wherein the spline shaft (<NUM>) includes a cam surface and a pulley channel (<NUM>) extending circumferentially around the axis of rotation (<NUM>), wherein the spline shaft (<NUM>) is pivotable between an unactuated position and an actuated position; and
a pulley (<NUM>) pivotally coupled to the boss (<NUM>; <NUM>") around the axis of rotation (<NUM>), wherein the pulley (<NUM>) includes an engagement surface and an upper pulley channel (<NUM>) extending circumferentially around the axis of rotation (<NUM>), wherein the pulley (<NUM>) is pivotable between a second unactuated position and a second actuated position, wherein:
the pulley (<NUM>) is spaced between the spline shaft (<NUM>) and the rear housing (<NUM>; <NUM>");
the upper pulley channel (<NUM>) in the pulley (<NUM>) axially aligns with the pulley channel (<NUM>) in the spline shaft (<NUM>); and
the cam surface of the spline shaft (<NUM>) is configured to frictionally engage with the engagement surface on the pulley (<NUM>) as the spline shaft (<NUM>) rotates towards the actuated position.