Patent Document

This application claims the benefit of both (i) U.S. Provisional Application Ser. No. 60/619,182, filed Oct. 15, 2004, and (ii) U.S. Provisional Application Ser. No. 60/718,458, filed Sep. 19, 2005. The disclosure of both of the above-identified provisional patent applications are hereby totally incorporated by reference in their entirety. 

   BACKGROUND 
   This invention relates to the field of child seats for motor vehicles. 
   Child seats for motor vehicles are widely used by operators of motor vehicles to protect children from harm in the event of an accident. Child seats generally include a plastic shell with a cushioned seat formed over the shell. A harness is provided on the seat to restrain the child and retain the child in the seat in the event of an accident. Harness systems typically include a shoulder harness with belts designed to extend over the shoulders of the child and a buckle harness with a crotch belt designed to extend between the legs of the child. The belts included with the harness system can typically be adjusted in length to accommodate children of different sizes. 
   A continuing challenge for users of conventional child vehicle seats and restraint systems is properly positioning the harness upon the child. In particular, the shoulder belts included with the shoulder harness should extend from the back of the seat within a specified range of the child&#39;s shoulder. In addition, the crotch belt of the buckle harness should extend from the bottom of the seat within a specified range of the child&#39;s crotch. Furthermore, the buckle of the buckle harness should be properly positioned within a specific range near the midsection of the child. Users of child seats are often required to make various adjustments to the harness such that all belts and buckles are properly situated for the child that will be using the seat. Therefore, a need exists for a child seat where the shoulder harness and buckle harness are easily and/or automatically adjusted, depending upon the size of the child. Furthermore, a need exists for a child seat where the position of the belts with respect to the seat may be changed depending upon the size of the child. Preferably, this would include automatically changing the position of the shoulder belt with respect to the back of the seat and automatically changing position of the crotch belt with respect to the seat bottom, depending upon the size of the child. 
   Another challenge for users of conventional child seat designs is the relative complexity of the headrest and shoulder harness adjustment for the seat. The headrest and shoulder harness positions should typically be adjusted as the child grows. However, the adjustment mechanisms for the headrest and/or shoulder harness can be awkward and difficult to manipulate on many seats. Therefore, it would be desirable to provide a headrest mechanism for a child seat that is easy to adjust. It would also be desirable to provide a harness system that is automatically adjusted when the headrest is adjusted, thereby relieving users of the need to readjust the harness after moving the headrest. 
   SUMMARY OF THE INVENTION 
   In accordance with one embodiment of the present invention, there is provided a child vehicle seat that includes a seat portion and a headrest assembly. The headrest assembly defines at least one belt aperture. The headrest assembly is movable in relation to the seat portion between an upper position and a lower position. The child vehicle seat further includes a harness system including (i) at least one shoulder belt portion extending through the at least one belt aperture defined in the headrest assembly, and (ii) a crotch belt assembly that is movable in relation to the seat portion between an extended position and a retracted position. Movement of the headrest assembly in relation to the seat portion from the upper position to the lower position causes the crotch belt assembly to move from the extended position to the retracted position. 
   In accordance with another embodiment of the present invention, there is provided a child vehicle seat that includes a seat portion and a headrest assembly that is movable in relation to the seat portion, the headrest assembly defining at least one belt aperture. The child vehicle seat further includes a harness system including (i) at least one shoulder belt extending through the at least one belt aperture defined in the headrest assembly, and (ii) a crotch belt that is movable in relation to the seat portion Movement of the headrest assembly in relation to the seat portion causes movement of the crotch belt in relation to the seat portion. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a partial cutaway perspective side view of a child vehicle seat and restraint system; 
       FIG. 2  shows a perspective view of a frame of the child vehicle seat of  FIG. 1 ; 
       FIG. 3  shows a front perspective view of the child vehicle seat of  FIG. 1  with the seat cover and foam shell removed; 
       FIG. 4  shows a rear perspective view of the child vehicle seat of  FIG. 1  with the headrest and seat cover removed; 
       FIG. 5  shows a rear view of the child vehicle seat of  FIG. 1 ; 
       FIG. 6  shows a front perspective view of the foam shell of the child vehicle seat of  FIG. 1 ; 
       FIG. 7  shows a front perspective view of the child vehicle seat of  FIG. 1  with a seat cover and headrest foam removed and the headrest in a down position; 
       FIG. 8  shows a front perspective view of the child vehicle seat of  FIG. 7  with the headrest in an up position; 
       FIG. 9  shows a front perspective view of the headrest support of the child vehicle seat of  FIG. 1  with the headrest removed from the headrest support; 
       FIG. 10  shows a fully assembled front perspective view of the child vehicle seat of  FIG. 1 ; 
       FIG. 11  shows a rear perspective view of the child vehicle seat of  FIG. 10 ; 
       FIG. 12  shows the harness arrangement in relation to the frame for the child vehicle seat of  FIG. 1 ; 
       FIG. 13  shows a front perspective view of the harness of the child vehicle seat of  FIG. 12  with the harness unbuckled; 
       FIG. 14  shows a top perspective view of the child vehicle seat of  FIG. 13  with a crotch strap in an extended position; 
       FIG. 14A  shows a top perspective view of an alternative embodiment to the arrangement shown in  FIG. 14  in which a tether belt is utilized to limit upward movement of the front buckle, and showing the crotch strap in an extended position; 
       FIG. 15  shows a top perspective view of the child vehicle seat of  FIG. 13  with a crotch strap in a retracted position; 
       FIG. 15A  shows a top perspective view of the alternative embodiment of  FIG. 14A  in which the crotch strap is shown in a retracted position; 
       FIG. 16  shows a front view of the headrest support of the child vehicle seat of  FIG. 1 , and showing the adjustment bar; 
       FIG. 16A  shows a front view of an alternative embodiment of a headrest support of the child vehicle seat, and showing an alternative embodiment of the adjustment bar in relation to that shown in  FIG. 16 ; 
       FIG. 17  shows a partial cutaway top perspective view of the child seat of  FIG. 1  exposing the retractor and latch mechanism; 
       FIG. 18  shows a front perspective view of the retractor mechanism of  FIG. 17 ; 
       FIG. 19A  shows a cross-sectional view of the belt retractor of  FIG. 17 ; 
       FIG. 19B  shows a rear elevational view of the belt retractor of  FIG. 19A ; 
       FIG. 19C  is a cross-sectional view of the belt retractor taken along the line A-A of  FIG. 19A ; 
       FIG. 20  shows a bottom perspective partial cutaway view of the child vehicle seat of  FIG. 1 ; 
       FIG. 21  shows a top front perspective view of an alternative embodiment of the child vehicle seat of  FIG. 1  with a removable seat cover; 
       FIG. 21A  shows an alternative embodiment of the headrest cover in relation to the headrest cover shown in  FIG. 21 ; 
       FIG. 22  shows another top front perspective view of the child vehicle seat of  FIG. 21  with the seat cover partially removed; 
       FIG. 23  shows an alternative front perspective view of the shoulder belts of the child vehicle seat of  FIG. 13 ; 
       FIG. 24  shows a front perspective view of the shoulder belts and shoulder pads of  FIG. 23 ; 
       FIG. 25  shows a rear perspective view of the child vehicle seat of  FIG. 1  including a carrying strap; 
       FIG. 25A  shows a rear perspective view of an alternative embodiment of the child seat in relation to the embodiment shown in  FIG. 25 , with the alternative embodiment including an anti-skid material adhered or otherwise affixed to the bottom surface of the bottom portion of the base shell of the child seat; 
       FIG. 26  shows a rear perspective view of the child vehicle seat of  FIG. 25  with the carrying strap hooked to the vehicle seat; 
       FIG. 27  shows a perspective view of the child vehicle seat of  FIG. 25  being carried by a user; 
       FIG. 28  shows a top view of the child vehicle seat of  FIG. 21 ; 
       FIG. 29  shows a top perspective view of the child vehicle seat of  FIG. 28  with the instruction flap pulled back; 
       FIGS. 30A and 30B  show perspective views of two separated locking pieces of a fastener for the child vehicle seat of  FIG. 21 ; 
       FIG. 31  shows a perspective view of the locking pieces of  FIG. 30  in an engaged position; and 
       FIG. 32  shows a page of an instruction manual for the child vehicle seat of  FIG. 1 . 
   

   DESCRIPTION 
   Overview 
   With general reference to  FIG. 1 , a child&#39;s vehicle seat and restraint system  100  comprises a seat portion  104  and a headrest  102 . The seat portion  104  of the child seat  100  includes a base shell  118  which is secured to the posterior side of a rigid frame  122 . A foam shell  120  is secured to the base shell  118  and covers the anterior side of the rigid frame. The headrest  102  is attached to an adjustable headrest support  130  which is slideably retained upon the frame. 
   As shown in  FIG. 12 , the child seat  100  also includes a harness  110  which is designed to secure an occupant within the seat. The harness  110  includes a plurality of straps that form a web  200  used to secure a child in the seat. The harness  110  also includes a front buckle  112  and a front clip  114  used to properly position the harness straps upon the child. A central belt retractor  300  is secured to the rigid frame  122  and is operable to remove slack in the harness once a child occupant is positioned in the child seat  100 . 
   Frame 
   With reference to  FIG. 2 , the frame  122  of the child seat includes two L-shaped members  126  separated by a plurality of metallic cross members  128  that extend between the L-shaped members  126 . The cross members  128  extend through holes defined in the L-shaped members  126  and are fastened to the L-members using means commonly used in the art, such as welding or nuts and bolts. Each L-shaped member includes a short leg  132 , a curved portion  134 , and a long leg  136 . Two parallel support bars  138  are also included in the frame. Each support bar  138  includes a first end connected to the short leg  132  of one of the L-shaped members  126  and a second end that extends toward the top of the long leg  136  of the same L-shaped member  126 . An S-shaped plate  140  connects the second end of each support member to the long leg  136  of the L-shaped member  126 . One of the cross members  128  extends through the first end of the support bars  138  to secure the support bars to the short legs  132  of the L-shaped members  126 . An additional metallic cross member  129  is provided that extends between the support bars  138  and through the S-shaped plates. The rigid frame  122  is made of a lightweight metallic material, such as aluminum. 
   The frame  122  generally provides a strong skeletal structure for the child seat  100  to which all load bearing components on the child seat are attached. Because the frame  122  is comprised of a metal material, the frame provides a stable support that resists cracking and/or breaking. With this arrangement, force is directed away from the occupant of the child seat in the event of a crash. 
   Base Shell 
   With reference to  FIGS. 1 and 3 , the base shell  118  cradles the frame  122  about the posterior side of the frame  122 . To this end, the profile of the base shell  118  is generally L-shaped, similar the L-shaped members  126  of the frame  122 . The base shell  118  is made of a relatively stiff plastic material, such as polypropylene. The base shell  118  includes a bottom portion  150  designed to receive the short legs  132  of the frame  122 , and a back portion  152  designed to receive the long legs  136  of the frame  122 . The frame  122  is secured to the base shell  118  in any means commonly used in the art such as rivets, nuts and bolts, or other fasteners. 
   As shown in  FIGS. 4 and 5 , the back portion  152  of the base shell  118  includes a recessed angled panel  156  positioned between two rear heels  158 . A window  160  is formed in the back portion  152  above the recessed angled panel  156 . The window  160  is flanked by two side wings  162 . A top panel  164  is formed above the window  160  and extends between the two side wings  162 . Two columns  166  extend from the top panel  164  down to the heels  158 . The two columns  166  partially surround the long legs  136  of the L-shaped members  126  of the frame  122 . Triangular openings  168  are formed between the wings  162 , columns  166  and heels  158 , as shown in  FIG. 4 . 
   The bottom portion  150  of the base shell  118  includes a generally flat portion designed to provide a surface for the base shell that rests upon the vehicle seat. The bottom portion  150  of the base shell is best seen in  FIGS. 25 and 26 . Anti-skid material may be adhered or otherwise affixed to the bottom surface of the bottom portion  150  of the base shell to discourage the base shell from moving when it is placed in a vehicle seat as shown in an alternative embodiment depicted in  FIG. 25A . The anti-skid material is generally a resilient material such as rubber or soft plastic and is textured to provide additional gripping ability on a vehicle seat. 
   The two rear heels  158  also blend into the bottom portion  150  of the base shell and provide additional support for the base shell when it is placed in the vehicle seat. The bottom portion  150  of the base shell  118  is cupped by the two side wings  162  which extend down from the back portion  152  and into the bottom portion  150  of the base shell. The short legs  132  of the frame  122  are located in the cupped bottom portion. As shown in  FIG. 14 , the bottom portion  150  of the base shell  118  also includes a central channel  154  through which a harness belt passes. 
   Foam Shell 
   With reference now to  FIG. 6-8 , the top foam shell  120  is generally a single integral component. The foam shell generally comprises a seat  170  and a backrest  172 . Two arm rests  174  flank the seat  170 , and a recess  176  is formed in the front of the seat, as shown in  FIG. 6 . The arm rests flow into two sidewalls  178  that flank the backrest  172 . An opening is formed in the backrest for receiving the adjustable headrest support  130 . The foam shell  120  is made of a dense foam material, such as ethylene propylene copolymer, with a density ranging between 20 g/l and 180 g/l. In one preferred embodiment, the dense foam material is ethylene propylene copolymer with a density of 30 g/l. Such foam material is sold by JPS International under the trademark ARPRO® expanded polypropylene beads. The foam shell is relatively flexible compared to the more rigid portions of the child seat  100 , and is designed to cradle the occupant of the child seat in the event of side impacts. The foam shell is soft to the touch and is configured to absorb a significant amount of energy in the event of a crash. In addition, extreme temperatures have relatively little effect on the foam shell so that cracking of the foam shell does not occur in the event of a vehicular accident. The foam shell is designed and configured to cushion the occupant and protect the occupant in the event of an accident. 
   As described above, the foam shell is positioned over the anterior sides of the frame  122  and base shell  118 . The frame  122  is thus generally enclosed by a two-part shell which includes the base shell  118  on one side and the foam shell  120  on the other side. The foam shell  120  is secured to the frame  122  and/or base shell  118  using any of various fastening methods known to those of ordinary skill in the art. For example, the foam shell  120  may be secured to the base and frame using hook and loop type fastener strips, such as those sold under the trademark VELCRO®, or nuts and bolts or other fasteners. 
   An exemplary fastener  360  which may be used to secure the foam headrest  102  to the headrest support  130  is shown in  FIGS. 30A ,  30 B, and  31 . The fastener  360  includes two complementary molded locking pieces  362  and  364 . Each locking piece includes a circular anchor  366  with an extending post  368 . The extending post includes two opposing tines  370  and  372 . Each tine  370 ,  372  includes a first plurality of teeth  374  axially positioned along one interior side and a second plurality of teeth  376  axially positioned along another interior side such that the first plurality of teeth  374  are 90° offset from the second plurality of teeth  376 . When the posts  368  are mated, the tines  370 ,  372  from one locking piece  362  slide along the tines  370 ,  372  of the opposite locking piece  364 , and the teeth  374 ,  376  on the tines act in a ratcheting fashion, such that the posts  368  can only become further engaged, and are locked from disengagement. When the posts  368  are fully engaged, the locking pieces  362 ,  364  are fastened and cannot be pulled apart without destruction of the locking pieces. When used on the seat  100 , the circular anchor  366  from one locking piece  362  is embedded in the foam shell with its post  368  extending through a hole  363  defined in the foam headrest  102  (see, e.g.,  FIG. 1 ). The post  368  of the other locking piece  364  extends through a hole  365  defined in the headrest support  130  (see, e.g.,  FIGS. 7 and 8 ). When the two posts  368  are engaged, the ratcheting action on the teeth locks the posts together, thereby securing the foam headrest  102  to the headrest support  130 . 
   Headrest Support 
   With reference to FIGS.  1  and  7 - 9 , the headrest support  130  is generally rectangular in shape and is adjustably mounted on the parallel support bars  138  of the frame  122 . The headrest support  130  includes a front face  182  and a rear face  184 . As best seen in  FIG. 9 , u-shaped channels  190  are positioned along the edges of the headrest support. The u-shaped channels  190  are designed to curve around and receive the support bars  138 , thus guiding the headrest support  130  as it slides up and down along the support bars  138 . The headrest support  130  includes a forward portion  131  (see, e.g.,  FIGS. 7 and 8 ) and a rear portion  133  (see, e.g.,  FIG. 9 ). The forward portion  131  and the rear portion are secured together, and thus, move in unison during adjustment of the headrest support  130 . 
   As discussed above, the headrest is mounted directly on the headrest support  130 . For example, fasteners  360 , such as those shown in  FIGS. 30A ,  30 B, and  31  may be used to secure the headrest  102  to the headrest support  130 . In an alternative embodiment, a resilient foam material is interposed between the forward portion  131  of the headrest  130  and the rear portion  133  of the headrest  130 . The resilient foam material provides cushioned support for the headrest. 
   The front face  182  of the headrest support  130  also includes two belt guides  186 . The two belt guides  186  extend from the front face  182  and provide for passage of the harness straps  200  through the headrest support. The headrest  102  includes holes designed to allow the belt guides  186  to extend through the foam cushion of the headrest. As explained in further detail below, the belt guides  186  also properly position the harness straps at various vertical heights as the headrest support  130  and headrest  102  are moved to account for children of different sizes in the child seat  100 . A slit  198  is also defined in the headrest support  130  to provide an additional passage from the front face  182  to the rear face  184 . As explained in further detail below, the slit  198  is designed to receive the end of one of the harness belts, and secure it to the headrest support  130 , thereby assisting in automatically adjusting the harness as the headrest support  130  and headrest  102  are moved. 
   Also included on the front face  182  of the headrest support  130 , behind the headrest  102 , is a panel adjustment mechanism  148 . With reference to  FIGS. 9 and 16 , the panel adjustment mechanism includes a horizontal center track  191  defined in the headrest support  130 . Two pins  193  are positioned in the horizontal center track  191 . The two pins  193  are biased toward the outer edges of the track  191  by a center spring  192 . Each pin  193  includes a locking post (not shown) designed to extend out of an end the track  191  and into one of a plurality of holes  149  in the support bar  138  of the frame. However, each of the two pins  193  are slideable within the track  191  such that the locking posts may be removed from the holes  149  in the support bar if the pins  193  are moved a sufficient distance toward the center of the track  191  against the bias of center spring  192 . A knob  194  is provided on each pin  193  to facilitate movement of the pin within the track  191 . As best seen in  FIG. 16 , each knob  194  extends out of the track and contacts an angled cam surface  146  on the end of an adjustment bar  144  that is slideably mounted to the front face  182  of the headrest support  130 . The angled cam surface  146  is defined by two angled slots  187  (see, e.g.,  FIG. 16A ) such that opposing sides of the surface are further apart near the bottom than at the top. The opposite end of the adjustment bar  144  includes a handle  142  (see  FIGS. 7-8 ). The handle  142  is spring biased in a downward position. 
   According to the above arrangement, when a user pulls up the handle  142 , the adjustment bar  144  slides upward and the angled surface  146  of an angled slot also moves upward. As the angled cam surface  146  slides upward, the knobs  194  on the pins  193  ride along the angled cam surface, forcing the pins  193  closer together, toward the center of the track. When the pins  193  are moved to the center of the track, the locking posts on the pins are removed from the holes  149  in the support bar  138 . Accordingly, the headrest support  130  and connected headrest  102  are free to slide along the support bar  138 . When the proper position for the headrest  102  is found, the user releases the handle  142  and the handle returns to a downward position. As the handle  142  returns to the downward position, the adjustment bar  144  and angled cam surface  146  also move downward, allowing the knobs  194  on the pins  193  in the track  191  to move further apart. The spring  192  then forces the pins apart, thereby forcing the locking posts into the holes  149  in the support bar  138  when the locking posts are properly aligned with the holes  149 .  FIG. 16  shows an alternative embodiment of an adjustment bar  144 ′ possessing an alternative camming arrangement configured generally to possess an inverted U-shape or inverted V-shape. With such an alternative arrangement, the operator would push down on the handle  142  in order to remove the pins  193  from the corresponding holes  149  defined in the support bar  138  so that the headrest support  130  could be adjusted. 
   Headrest 
   With reference to  FIGS. 1 ,  10  and  11 , the headrest  102  is mounted on the top portion of the headrest support  130 . The headrest  102  is comprised of the same material as the foam shell  120 . In particular, the headrest is comprised of a dense foam material, such as ethylene propylene copolymer. Such foam material is commercially available through JPS International under the trademark ARPRO® expanded polypropylene beads. 
   The headrest  102  includes a central portion  101  that is secured to the headrest support  130 . The central portion  101  includes two shoulder harness slots  105  that are aligned with the harness guides  186 , allowing straps to pass through the headrest support  130  and headrest  102 . The central portion  101  of the headrest  102  is integral with two flexible sidewalls  103  having generally curved perimeters. Each sidewall  103  extends about 6 to 12 inches outward and away from the location where the central portion  101  is attached to the headrest support  130 . Each sidewall  103  also curves around the base shell  118  as it extends away from the central portion  101 . While the central portion  101  is securely fastened to the headrest support  130 , the sidewalls  103  are free to bend in relation to the central portion  101 . In particular, the sidewalls  103  of the headrest  102  are free to pivot near the point where the headrest  102  is fastened to the headrest support  130  and toward an occupant&#39;s head sitting in the child seat  100  in the event of an accident. This provides a significant amount of protection for the occupant of the seat  100  in the event of a side impact to the vehicle or a rollover. The dense foam material that forms the headrest  102  not only cradles the occupant&#39;s head in the event of an accident, but also serves as a cushion for sleeping. 
   Any number of different types of fasteners may be used to secure the headrest to the headrest support. For example, the fasteners  360  described above with two locking pieces  362 ,  364  may be used to secure the foam of the headrest  102  to the headrest support  130 . Alternatively, loop and hook fastener material, such as VELCRO®, may be positioned on the back side of the headrest  102  and used to secure the headrest  102  to the headrest support  130 . Low-density foam cushioning  124  may be attached to the headrest and headrest support to provide comfort padding for the back and head of the occupant of the child seat. 
   Seat Cover 
   As shown in  FIGS. 10 and 11 , a seat cover  108  covers the seat portion  104 , and a headrest cover  109  covers the headrest  102 . Foam cushioning  124  is placed on the foam shell, under the seat cover  108 , to make the seat  100  more comfortable for the occupant. The seat cover  108  and headrest cover  109  provide a comfortable feel to the seating surface of the child seat  100  and also provide an aesthetically pleasing and desirable look to the child seat. The seat cover and headrest cover may be constructed from any material that is conventionally used with seats in the automotive vehicle industry, such as leather, vinyl, cloth, or the like, or any materials used as cover materials in the juvenile furniture industry, such as polyester, terry cloth, or the like. 
   In one embodiment, the seat cover  108  is designed for removal from the foam shell  120  and base shell  118  without the need to remove any straps from the harness of the child seat  100 . This embodiment is generally shown with reference to  FIGS. 21 and 22 . In this embodiment, the seat cover  108  and headrest cover  109  include a plurality of slits  380 - 384  and a plurality of flaps  390 - 394 . The slits and flaps allow the seat cover  108  and headrest cover  109  to be manipulated around the harness straps. For example, slit  384  allows the buckle  112  of the buckle harness system  211  (described below) to pass through the slit  384 , and flap  394  may be opened to re-insert the buckle through the slit when reattaching the cover to the seat. The backrest flaps  390  and  392  and slits  380  and  382  are other slits that may be manipulated when removing or attaching the cover. Seat cover fasteners, for example hook and loop type fasteners such as VELCRO®, are used to connect the slits and flaps and secure them in place on the seat while also providing a smoother more uniform appearance to the seat. The periphery of the seat cover  108  is designed to overlap the edges of the base shell  118 . The periphery  198  of the seat cover  108  is lined with an elastic material that helps retain the seat cover  108  on the base shell  118 . 
   Harness System 
   The harness system  110  is generally shown with reference to  FIGS. 12-16 . The harness system  110  includes a web  200  comprised of a plurality of belts/straps as well as several buckles. As shown in  FIG. 12 , the harness system  110  may be considered a two-part system, including a shoulder harness system  201  and a buckle harness system  211 . The configuration of the plurality of harness belts in relation to the frame are described for both the shoulder harness system and the buckle harness system with reference to  FIG. 12 . Thereafter, features of the harness system are described in relation to other portions of the child seat  100 . 
   Shoulder Harness System 
   With reference to  FIG. 12 . The shoulder harness system  201  includes a shoulder belt  202  that includes a first end  204  fastened to one port of a Y-connector  250  and a second end  206  fastened to another end of a Y-connector  250 . Starting with the first end  204 , the shoulder belt moves up from the Y-connector  250 , over the cross member  129 , and down under the frame  122 . After passing under the two short legs  132  of the L-shaped members  126 , the shoulder belt  202  is passed back up to the cross member  129  on the other side of the frame  122 . The shoulder belt  202  then loops over the cross member  129  on the opposite side of the cross member from where it originally looped over, and follows back down to the Y-connector  250 , where the shoulder belt  202  terminates and is again fastened to the Y-connector (also see  FIG. 4 ). The other belt fastened to the Y-connector  250  is a retraction belt  208 . The retraction belt moves down along the angled panel  156  of the base shell and, after making turn, passes into the central channel of the base shell. A dotted line  118  is provided in  FIG. 12  to represent this portion of the base shell  118  in relation to the frame  122 . After passing through the central channel of the base shell, the retraction belt  208  feeds into the retractor (represented by dotted line  300 ). In particular, the end of the retraction belt is fastened to the feed bar  302  of the retractor. The feed bar may be turned in the direction of arrow  232  using knob  234  (also see  FIG. 1 ) to wind the retraction belt  208  in the retractor  300 , thereby tightening the shoulder belt  202  and helping to secure an occupant in the child seat  100 . Conversely, the knob  234  and feed bar  302  may be turned in the direction opposite arrow  232  to pay out additional portions of the retraction belt  208  from the retractor, thereby providing additional slack for the shoulder belt when a larger occupant is seated in the child seat  100 . 
   Referring now to  FIGS. 13-16 , the shoulder harness system is shown with respect to the frame  122 , base shell  118 , and headrest support  130 . As shown in  FIG. 13 , the shoulder belt  202  passes through both belt guides  186  on the headrest support  130  as the shoulder belt  202  winds over cross bar  129  and under the bottom portion of the base shell  118 . Although the shoulder belt  202  passes through the belt guides  186  on the headrest support  130 , the shoulder belt only slideably engages the belt guides and does not connect to the belt guides. This allows the headrest support  130  and attached headrest  102  to move up and down upon the frame  122  and move to various positions, as discussed above, without the need for removal, loosening or other adjustment of the harness  110 , including the shoulder belt  202 . Accordingly, the headrest  102  and associated mechanism is independent of the harness  110 . Furthermore, this arrangement of the harness shoulder belt  202  passing through the belt guides  186  means that the headrest is not a load-bearing component of the child seat  100 . The arrangement of the shoulder belt  202  upon the frame  122  means that most of the load is applied to the frame in the event of a crash. The headrest may be adjusted to any position without loosening the harness. 
   Buckle Harness System 
   Referring again to  FIG. 12 , the harness belts  200  of the child seat further comprise belts in a buckle harness system  211 . The buckle harness system  211  includes a crotch adjustment belt  214  and a crotch belt  220 . A first end  216  of the crotch adjustment belt  214  is inserted through the slit  198  in the headrest support  130  (represented by dotted lines  130  in  FIG. 12 ) and is fastened to a buckle  260 . The buckle  260  secures the first end  216  to the headrest support  130 , since the buckle is prevented from passing through the slit  198  to the headrest support  130  (as shown in  FIG. 16 ). The crotch adjustment belt  214  extends up from the buckle  260  and over the center portion of the cross bar  129 . Then, the crotch adjustment belt  208  passes down to the cross bar  128   c  and turns toward cross bar  128   b . After passing under cross bar  128   b , the crotch adjustment belt  208  is fastened to crotch adjustment bar  128   a . An adjustable connector  240  is looped around the crotch adjustment belt  208  between the cross bars  128   a  and  128   b  such that the adjustable connector  240  is free to slide upon the crotch adjustment belt  214 . One end of a crotch belt  220  is securely fastened to the adjustable connector  240 . The opposite end of the crotch belt  220  is connected to the buckle  112 . As the headrest support  130  and associated first end  216  of the crotch adjustment belt  214  move up, slack is provided in the crotch adjustment belt  214 . This slack allows the buckle  112  connected to the crotch belt  220  to extend further away from cross bars  128   a  and  128   b . Conversely, when the headrest support  130  and associated first end  216  of the crotch adjustment belt  214  move down, the crotch adjustment belt  214  is tightened and less of the belt is available between cross bars  128   a  and  128   b . With less belt available between these cross bars, the fastener  240  and buckle  112  are pulled downward toward the cross bars  128   a  and  128   b.    
   Referring now to  FIGS. 14-15 , the crotch adjustment belt  214  is shown in two different positions. In  FIG. 14 , the crotch belt  214  is in an extended position. In this extended position, the headrest support  130  and headrest  102  are moved fully up, providing slack in the crotch adjustment belt  214  that allows the adjustable connector  240  and attached crotch belt  220  to move to the extended position. In  FIG. 15 , the crotch adjustment belt is in a retracted position. In this retracted position, the headrest support  130  and headrest  102  are moved fully down, taking up slack in the crotch adjustment belt  214  to move the crotch belt  220  to its retracted position. In this retracted position, a spacer  222  is shown encouraging the adjustable connector  240  more rearward. The spacer  222  is a plastic material that prevents the adjustable connector from contacting the portion of the belt  214  covered by the spacer  222 . Therefore, when little slack is available in the belt  214 , the adjustable connector and associated crotch belt are encouraged toward the back of the seat. Accordingly, as the headrest  102  is moved up for taller (and larger) occupants, the buckle harness available to the occupant lengthens and moves toward the front of the child seat. As the headrest is moved down, the buckle harness available to the occupant reduces in length and moves toward the rear of the seat. Accordingly, a child seat is provided that includes a buckle harness system  211  that automatically adjusts to the size of the occupant, based on the location of the headrest  102 . In an alternative embodiment shown in  FIGS. 14A and 15A , the front buckle  112  is not slidable along the crotch adjustment belt  214  as is the case in the embodiment shown in  FIGS. 14 and 15 . Rather, the front buckle  112  is attached to one end of the belt  214  as shown in  FIGS. 14A and 15A . A tether belt  221  is added to limit upward movement of the front buckle  112 . To this end, one end of the tether belt  221  is secured to the cross bar  128   b  while the other end of the tether belt  221  is secured to the one end of the belt  214  as shown in  FIGS. 14A and 15A . 
   Altogether, the disclosed harness system  110 , including the shoulder harness system  201  and buckle harness system  211  provide means of adjusting the shoulder and crotch strap heights to better fit with ideal belt positioning for children of various ages. Together, the shoulder harness system  201  and the buckle harness system  211  provide an integrated child restraint system that can be adjusted to ideally restrain children of various weights and sizes. In one embodiment, the integrated child restraint system is designed for restraining children from 22-65 lbs. The restraint system includes a means to adjust shoulder belt heights while simultaneously positioning the crotch belt height and fore and aft position. 
   Central Belt Retractor 
   With reference to FIGS.  1  and  17 - 20 , a central belt retractor  300  is provided on the front portion of the base shell  118 . As shown in  FIG. 1 , a decorative and protective covering  330  generally shields the central retractor  300  when the seat is assembled. Removal of the protective covering  330  exposes the retractor  300 . 
   As best shown in  FIG. 18 , the central retractor  300  includes a spool  306  and latch  116  that cooperate in a ratchet fashion to wind the retraction belt  208  on the spool. The spool  306  is retained within a retractor housing  304  that is secured to cross bar  128   a . The spool  306  is mounted to an axle  302  that extends through the housing  304 . As shown in  FIGS. 19A-19C , a wound power spring  320  connects the spool  306  to the axle  302  and biases the spool toward clockwise movement, in the direction of arrow  350 , which will wind the retraction belt  208  on the spool. The spool  306  includes two circular sidewalls  308  with ratchet teeth  310  formed on the circular sidewalls. As shown in  FIGS. 17 and 20 , a handle  324  is fixed to the end of the axle  302  to allow for manual rotation of the axle  302  and spool  306 . In particular, manual rotation of the handle  324  by a user will cause the retraction belt  208  to be wound upon the spool. As described previously, because the retraction belt  208  is connected to the shoulder harness system  201 , winding the retraction belt  208  upon the spool will tighten the retraction belt  208  and shoulder belt  202  and generally tighten the shoulder harness on an occupant of the seat. 
   Returning to  FIG. 18 , the latch  116  is provided for locking the spool  306  in place. The latch  116  includes a front handle  318  and two pawls  312  that extend rearwardly from the front handle  318 . Each pawl  312  includes a plurality of pawl teeth  310  designed to engage the spool teeth  310  in a ratchet fashion. The latch  116  includes two pivot posts  316  that connect the latch to the retractor housing  304 . The latch  116  also pivots within the housing  304  on the pivot posts  316 . The front handle portion  318  of the latch  116  is biased downward by two springs  326 . Because the latch  116  is biased downward, the pawl teeth  314  are encouraged toward engagement with the spool teeth  310 . 
   Rotation of the spool  306  in the clockwise direction, as noted by arrow  350  in  FIG. 18 , results in the retraction belt  208  winding upon the spool  306 . Because the spool  306  is spring biased, this rotation is generally automatic and acts to tighten the shoulder harness, as described above. Because of the ratchet action between the spool teeth  310  and the pawl teeth  314 , the spool is normally blocked from counter-clockwise rotation, opposite the direction of arrow  350 , which would allow the retraction belt  208  to be paid out. Furthermore, if the user wishes to take up additional slack in the retraction belt  208  and attached shoulder belt  202 , the handle  324  connected to the axis  302  may be rotated in the direction of arrow  350 , causing additional lengths of the retraction belt  208  to be wound upon the spool  306 , and thereby tightening the shoulder belt  202  upon the occupant of the seat. Additional lengths of belt wound upon the spool  306  are retained by the spool because of the ratchet action of the spool teeth  310  with the pawl teeth  314 . When the user desires to pay out previously wound lengths of the retraction belt  208  in order to loosen the connected shoulder belt  202 , the latch handle  318  is moved upward. Upward movement of the latch handle  318  releases the pawl teeth  314  from the spool teeth  310 . This separation allows the spool to rotate in a counter-clockwise direction, opposite the direction of arrow  350 , and pay out additional lengths of the retraction belt  208  when the shoulder harness system  201  is pulled outwardly. However, because the spool  308  is spring biased, slack in the retraction belt  208  and shoulder harness system  201  is removed once the user stops pulling on the shoulder harness system. In this fashion, the shoulder harness system automatically tightens upon the occupant of the child seat and secures the occupant in the seat. 
   Connection to Vehicle Seat 
   Returning to  FIGS. 1 ,  3 - 5 ,  13 ,  17 , and  20  a system is provided for mounting the child seat  100  in a vehicle. In particular, vehicle connection straps  270  are provided that are connected to vehicle connection buckles  280 . The connection straps are partially wound on retractable spools of retractors  290  (see  FIG. 20 ) located under cross bar  128   a . The retractors  290  for the vehicle connection straps  270  operate in a similar fashion to the retractor  300  for the retraction belt  208  and connected shoulder belts  202  (as described above with reference to  FIGS. 17-20 ). For example, similar to retractor  300 , the retractors  290  for the vehicle connection straps  270  are spring biased and automatically tighten the vehicle connection straps  270 . The retractors  290  may be released by pressing the buttons  284  located next to the retraction latch  116  on the bottom front portion of the seat. Depression of one of the buttons  284  rotates a lever that releases a pawl from engagement with teeth on the retractor  290 . When the pawl is otherwise engaged with the teeth, the pawl locks the retractor  290  from rotating in a direction that would pay out the vehicle connection strap  270 . When the pawl is released from the teeth by depression of the button  284 , the retractor  290  is allowed to rotate and pay out the vehicle connection strap  270 . In one embodiment, the buttons  284  are connected by a connecting bar such that depression of either button  284  will release both of the retractors  290 . It should be appreciated that the retractors  290  and the vehicle connection buckles  280  may, respectively, be constructed and operate in the same or similar manner to any of the retractors and vehicle connection buckles disclosed in Patent Publication No. US 2004/0084939, the disclosure of which is hereby totally incorporated by reference in its entirety. 
   The vehicle connection straps  270  extend horizontally from the spools of the retractor  290  along the bottom portion of the base shell  118 . At one of the cross members  128  of the frame  122 , the straps  270  make a perpendicular turn and extend vertically along the base shell. Thereafter, the connection straps pass through 45° slots  282  in the base shell  118 . The 45° slots  282  redirect the straps  270  in a generally horizontal direction such that the straps  270  extend sideways relative to the upright child seat  100 . The straps terminate in connection buckles  280  operable to connect to anchors in the vehicle seat. 
   In addition to the above method for connecting the vehicle seat to an automobile, the vehicle seat may also be secured to an automobile by passing the shoulder belt of the automobile through the triangular shaped openings  168  in the posterior portion of the base shell  118  and frame  122 . After passing the shoulder belt through the openings  168 , the belts may be buckled to the shoulder belt anchors of the vehicle seat belt and tightened, thus securing the child seat  100  to the vehicle seat. 
   Proper Harness Position Indicators 
   The child seat  100  is equipped with both a clip position indicator and a shoulder slot position indicator. The clip location indicator  396  is provided on the clip itself. The clip position indicator  396  includes a design, icon, wording, or other indicia to show the proper position of the clip relative to the child. For example, as shown in  FIG. 23 , the clip position indicator includes the words, “Adjust to armpit level.” As also shown in  FIG. 23 , shoulder pads  395  in the form of TPE pads are slideably positioned on the shoulder belts to provide shoulder padding for the child. As shown in  FIG. 24 , the shoulder pads  395  include a textured surface designed to provide friction against a child&#39;s clothing, and thus prevent the TPE pads from slipping on the child when the child is secured in the seat by the harness. 
   In an alternative embodiment shown in  FIG. 21A , the shoulder slot position indicator is provided on the headrest cover  109 . The shoulder slot position indicator includes a design, icon, wording, or other indicia to show the proper position of the shoulder slot relative to the child. For example, as shown in  FIG. 21A , the shoulder slot position indicator  398  includes a dotted line with words “Adjust this line above shoulders.” Together with the automated adjustment features of the child seat, the clip location indicator and the shoulder slot position indicator help the consumer with proper positioning of the seat harness on the child. 
   Carrying Strap/Tether Combination 
   With reference to  FIG. 25 , the child seat  100  includes a tether  500 . One end of the tether  500  is secured to an upper posterior cross member on the frame  122  (see  FIG. 12 ). The other end of the tether  500  is connected to a tether clip  502  that may be used to secure the tether  500  to a tether anchor in an automobile. The tether clip includes a hook portion  504  and a buckle portion  506 . 
   Conveniently, the tether  500  may also serve as a carrying strap. To this end, the child seat  100  includes a tether clip connection slot  510  on the posterior side of the base shell  118 . The tether clip connection slot  510  is dimensioned to receive the hook portion  504  of the tether clip. Adjacent to the tether clip connection slot is a buckle groove  512  dimensioned to receive the buckle portion  506  of the tether clip  502 . 
     FIG. 25  shows the tether clip connection slot with the tether clip  502  removed from the slot  510 .  FIG. 26  shows the tether clip connection slot  510  with the hook portion  504  of the tether clip  502  hooked in the slot  510  and the buckle portion  506  of the tether clip positioned in the groove  512 . As shown in  FIG. 27 , when the tether clip  502  is hooked in the slot  512 , a user may grab the tether  500  and place it over his or her shoulder as a means for conveniently carrying the child seat in back-pack fashion. The length of the tether/carrying strap  500  may be conveniently adjusted at the buckle portion  506 , to accommodate the size of the user. 
   Instruction Manual Storage 
   With reference to  FIGS. 28 and 29 , the child seat  100  includes a pouch  530  built into the headrest cover  109 . The pouch  530  in the headrest cover  109  is generally rectangular in shape and is dimensioned to receive the instruction manual for the child seat  100 . The pouch  530  is positioned on the top portion of the seat and the opening to the pouch is covered by a flap  532 . The flap  532  includes one edge that is fixed to the headrest cover, and an opposing edge that connects to the headrest cover using a fastener, such as a hook and loop fastener. As shown in  FIG. 29 , pulling the edge of the flap back exposes the opening to the pouch  530  in the headrest cover. 
   When the headrest cover  109  is properly positioned on the headrest  102 , the pouch  530  is situated in front of the foam headrest  102  and behind the exterior surface of the headrest cover  109 . Padding may be added between the pouch  530  and the headrest cover  109 . The pouch  530  provides a convenient location for storage of the instruction manual, allowing a user of the seat  100  to quickly and conveniently access the instruction manual when needed. This convenient location for storage of the instruction manual also helps the user avoid losing the instruction manual. 
   Color Coded Parts and Instruction Manual 
   The instruction manual, seat labels, and various parts of the child seat  100  are all color coded to help the user identify and properly operate different parts on the seat. With reference to  FIG. 32 , a page  550  from the instruction manual is shown. This page  550  shows the child seat  100  along with various component parts of the child seat. As noted by this page  550  of the instruction manual, portions of the manual and seat  100  color coded in yellow refer to the retractable harness  110  and related components. Other portions of the instruction manual and seat  100  color coded in gray refer to the vehicle connection buckles  280  and related components. Still other portions of the instruction manual and seat  100  color coded in red refer to the vehicle seat belt and components for attaching the seat  100  to the vehicle seat belt. Of course any other color may be substituted for the colors described above such as substituting the color black for the color gray. 
   As noted above, numerous text references in the instruction manual are highlighted in yellow to indicate to the reader that the text being read is in reference to the retractable harness system  110  of the seat  100 . Likewise, numerous parts on the seat  100  are yellow to help the user easily identify and understand proper operation of the retractable harness system when reading about the retractable harness system in the manual. For example, with reference to  FIG. 32 , the knob  234  and the retraction latch  116  (color not shown) are both yellow in color. Thus, when the reader identifies yellow text in the instruction manual, he or she may easily identify the component parts to which the instruction manual refers for operation of the retractable harness system. 
   Additional Embodiments Anticipated 
   The child vehicle seat and restraint system disclosed herein is designed for use in any moving vehicle, including, without limitation, cars, vans, trucks, airplanes, etc. Although the present invention has been described with respect to certain preferred embodiments, it will be appreciated by those of skill in the art that other implementations and adaptations are possible. Moreover, there are advantages to individual advancements described herein that may be obtained without incorporating other aspects described above. Therefore, the spirit and scope of the invention should not be limited to the description of the preferred embodiments contained herein.

Technology Category: 7