Vehicle seat assembly

CROSS REFERENCE TO RELATED APPLICATIONS

P-0001[0001] This application claims the benefit of U.S. Provisional Application No. 60/373,183 filed Apr. 17, 2002.

BACKGROUND OF THE INVENTION

P-0002[0002] This invention relates in general to improved seat assemblies for use in a vehicle and a method of installing the seat assemblies. Typically, seats for use in automotive and truck vehicles vary in size, shape, and style for each particular vehicle platform. Also, a particular vehicle platform can have different styles of seats which can be installed in the vehicle. The front seats of a vehicle can have different seat configurations, such as for example, a “bench” seat in which the seat is a single structure which extends along the width of the front compartment of the vehicle. More common however, is a “bucket” seat arrangement in which separate driver and passenger seats are independently mounted on the floor in the front compartment of the vehicle. It is also common to include a center storage console positioned between the driver and passenger bucket seats and mounted on the floor.

P-0003[0003] Typically, each different style of seat is manufactured with a unique internal frame structure providing strength to the seat. The size and shape of the frame structure generally conforms to the size, shape, and style of the seat as well as the mounting locations within the vehicle front compartment. Each seat is commonly manufactured with its own unique frame structure. Also, the mounting structures of the seats are generally not interchangeable between different vehicle platforms. Sometimes, customers wish to customize the appearance of the seats, for example, to appear more like a racing-type seat. In order to make such customization possible, it would be advantageous to implement methods and materials to easily replace portions of the vehicle seat without having to replace the entire seat assembly.

BRIEF SUMMARY OF THE INVENTION

P-0004[0004] This invention relates to an improved seat assembly for use in a vehicle. The vehicle seat assembly includes an elongated continuous frame member having an upper portion and a lower portion. A mounting assembly is attached to the lower portion of the frame member and is adapted to be mounted on the floor of a vehicle. A back support structure is attached to the upper portion of the frame member. A bottom support structure is attached to the lower portion of the frame member.

P-0005[0005] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

P-0006[0006]FIG. 1 is a front perspective view of a vehicle seat assembly in accordance with the present invention.

P-0007[0007]FIG. 2 is a rear perspective view of the vehicle seat assembly shown in FIG. 1.

P-0008[0008]FIG. 3 is a side elevational view in partial cross-section of the vehicle seat assembly shown in FIG. 1.

P-0009[0009]FIG. 4 is an exploded perspective view of the vehicle seat assembly shown in FIG. 1.

P-0010[0010] FIGS. <b>5</b>A-<b>5</b>D are cross sectional views of alternate embodiments of the cross-section of the spine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

P-0011[0011] There is illustrated in FIGS. 1 through 4, a vehicle seat assembly, indicated generally at <b>10</b>, in accordance with the present invention. The seat assembly <b>10</b> generally includes a mounting assembly <b>12</b> and a seat defined by a frame member or spine <b>14</b>, and a plurality of support structures, such as a headrest panel <b>16</b>, an upper back panel <b>18</b>, a lower back panel <b>20</b>, and a bottom panel <b>22</b>. The spine <b>14</b> is preferably a single elongated continuous member having a contoured shape which defines an upper portion <b>24</b>, an intermediate portion <b>25</b>, and a lower portion <b>26</b>. The lower portion <b>26</b> is attached to the mounted assembly <b>12</b>. Generally, the spine <b>14</b> provides the structural support for the seat assembly <b>10</b> such that forces acting on the structural supports, such as by movement and acceleration/deceleration of the occupant, are transmitted through the spine <b>14</b> to the mounted assembly <b>12</b>, and then to the vehicle floor or frame upon which the seat assembly <b>10</b> is mounted. As will be discussed in detail below, the support structures <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b> are preferably releasably attached to the spine <b>14</b> so that a different style seat assembly can be configured by alternating attachment of a plurality of differently shaped, textured or colored support structures.

P-0012[0012] The mounting assembly <b>12</b> can be any suitable structure which secures the spine <b>14</b> relative to the floor of the vehicle. Preferably, the mounting assembly <b>12</b> provides positional adjustment of the seat assembly <b>10</b> relative to the vehicle such as by mechanically or electrically operated adjustment mechanisms for adjusting the fore and aft position of the seat assembly <b>10</b>. For example, there is illustrated in FIGS. 3 and 4 an embodiment of a mounting assembly <b>12</b> which includes a pair of track mechanisms having an upper track <b>30</b> slidably mounted relative to a lower track <b>32</b>. The lower track <b>32</b> is attached to the frame or floor of the vehicle. A pair of cross bars <b>36</b> extend laterally between the upper tracks <b>30</b>. A support plate <b>38</b> is mounted on top of the cross bars <b>36</b> and is supported thereby. The lower portion <b>26</b> of the spine <b>14</b> is mounted on the support plate <b>38</b>, thereby attaching the seat to the mounting assembly <b>12</b>. A stop or detent mechanism can be operated via a handle <b>34</b> for selectively maintaining and releasing the upper tracks <b>30</b> relative to the lower tracks <b>32</b> to permit and restrict the fore and aft movement of the seat assembly <b>10</b> relative to the floor of the vehicle.

P-0013[0013] Preferably, the support plate <b>38</b> defines an upper surface <b>40</b> having a complimentary shape as a lower surface <b>42</b> of the lower portion <b>26</b> of the spine <b>14</b>. For example, the surfaces <b>40</b> and <b>42</b> can be arcuate or semi-circular shaped defined by a common radius. The support plate <b>38</b> and the lower portion <b>26</b> of the spine <b>14</b> may include a plurality of fastener devices, such as apertures and threaded fasteners, which permit an adjustable mounting to alter the pitch of the seat relative to the mounting assembly <b>12</b>. Thus, the spine <b>14</b> could be fastened to the support pate <b>38</b> at varying positions along the support plate <b>28</b>. The mounting assembly <b>12</b> could also include an adjustment mechanism for adjusting the vertical position of the front and/or rear portion of the seat. Of course, any other suitable mounting arrangement may be used to mount the seat onto the mounting assembly <b>12</b>.

P-0014[0014] The spine <b>14</b> is preferably an elongated continuous member which is relatively rigid to support the weight of the support structures, the occupant, and the forces acting thereon. The shape of the spine <b>14</b> and the attached support structures generally conforms to the contour of a seated occupant. The spine <b>14</b> can be made of a unitary piece of a generally rigid material, or can be made of a laminate or composite material. Examples of suitable materials for the spine <b>14</b> include metal (such as high strength steel or aluminum), fibrous material (such as carbon fiber, fiberglass, or other organic fibers, for example organic fibers sold under the trademark KEVLAR manufactured by duPont), and polymeric material (such as a blow molded structural foam). The spine <b>14</b> could also be formed from any combination of the materials listed as well as any other suitable materials used alone or in combination. While it is generally preferred that the spine <b>14</b> be made of a rigid material, it is anticipated that the spine <b>14</b> may flex or deform slightly while still adequately supporting the occupant. As will be discussed below, the seat assembly <b>10</b> can include a secondary frame member such as a pair of tubular arms <b>50</b> for providing additional support.

P-0015[0015] While the spine <b>14</b> has been shown as having a relatively thin slightly curved cross-sectional shape, as shown in FIG. 5A, it should be understood that the spine <b>14</b> can have any cross-sectional shape to provide additional structural support thereto to help prevent bending thereof. For example, there is illustrated in FIG. 5B an alternate embodiment of a cross-section of a spine <b>14</b><i>b </i>having a generally triangular shape defining an outwardly and rearwardly extending fin portion <b>52</b>. There is illustrated in FIG. 5C another alternate embodiment of a cross-section of a spine <b>14</b><i>c </i>having a generally triangular shape defining a hollow interior <b>54</b>. Optionally, the interior <b>54</b> may be filled with another material, such as structural foam to provide added strength. There is illustrated in FIG. 5D yet another alternate embodiment of a cross-section of a spine <b>14</b><i>d </i>formed from two separate components <b>56</b> and <b>58</b> attached together. The spine <b>14</b> could also include a decorative cover at least partially covering the structural portion of the spine <b>14</b>. For example, the spine <b>14</b><i>d </i>includes the relatively rigid components <b>56</b> and <b>58</b> which provide the structural integrity of the spine <b>14</b>. The spine <b>14</b>d further includes a decorative cover <b>60</b> covering a portion of the spine <b>14</b><i>d</i>. The cover <b>60</b> could cover all exposed areas of the spine <b>14</b><i>d</i>, such as the rear surface and the portions extending between the support structures. Alternatively, the cover <b>60</b> could conceal only a portion of the exposed spine <b>14</b><i>d. </i>

P-0016[0016] As stated above, the spine <b>14</b> is generally shaped to conform to the contour of a seated occupant. As best shown in FIG. 3, the upper portion <b>24</b> is generally vertically positioned for supporting the back of an occupant. The lower portion <b>26</b> is generally horizontally positioned for supporting the buttocks and legs of the occupant. Due to the contoured shape of a seated occupant, the spine <b>14</b> has a relatively sharp curve or bend at the intermediate portion <b>25</b> between the upper and lower portions <b>24</b> and <b>26</b>. To provide additional strength to the spine <b>14</b> to help prevent fracture or undesirable bending at the intermediate portion <b>25</b>, the intermediate portion <b>25</b> may be formed with a less abrupt curvature or can include integral or non-integral reinforcement structures, such as ribs or bracing to strengthen this area. It is also contemplated that the upper and lower portions <b>24</b> and <b>16</b> could be separate components joined together by a recliner mechanism for selectively positioning the upper portion <b>24</b> relative to the lower portion <b>26</b>.

P-0017[0017] Alternatively, the seat assembly <b>10</b> can include a secondary frame member to strengthen the spine <b>14</b>, particularly about the intermediate portion <b>25</b>. Any suitable structure which assists in preventing bending of the spine <b>14</b> at the intermediate portion <b>25</b> can be used as the secondary frame member. As an example of a suitable secondary frame member, the seat assembly <b>10</b> includes the pair of tubular arms <b>50</b>. Upper portions <b>64</b> of the arms <b>50</b> are attached to the rear surface of the upper portion <b>24</b> of the spine <b>14</b> by a mounting bracket <b>66</b>. Lower portions <b>68</b> of the arms <b>50</b> include laterally extending extensions <b>70</b>. The ends of the extensions <b>70</b> are attached to the upper tracks <b>30</b>. Since the lower portion <b>26</b> of the spine <b>14</b> is fixed relative to the upper tracks <b>30</b> via the support plate <b>38</b> and cross bars <b>36</b>, the lower portions <b>68</b> of the arms <b>50</b> are fixed relative to the lower portion <b>26</b> of the spine <b>14</b>. Thus, the arms <b>50</b> forming the secondary frame member have ends attached or fixed relative to the upper portion <b>24</b> and the lower portion <b>26</b> of the spine <b>14</b>. Preferably, the arms <b>50</b> have a contoured shape complimentary to the contoured shape of the spine <b>14</b>. If desired, the secondary frame member could include a single arm <b>50</b>, or a plurality of arms <b>50</b>.

P-0018[0018] The seat assembly <b>10</b> can include any number of support structures attached to the spine <b>14</b>. In the embodiment of the illustrated seat assembly <b>10</b>, there are four support structures including the headrest panel <b>16</b>, the upper back panel <b>18</b>, the lower back panel <b>20</b>, and the bottom panel <b>22</b>. The support structures can have any suitable contoured shape for supporting an occupant of the seat assembly <b>10</b>. The panels <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b> can be single panels or formed by a pair of left and right panels.

P-0019[0019] Preferably, each support structure includes a generally rigid structural panel and a flexible cushion member. For example, the headrest panel <b>16</b> includes a structural panel <b>16</b><i>a </i>and a cushion <b>16</b><i>b</i>. The upper back panel <b>18</b> includes a structural panel <b>18</b><i>a </i>and a cushion <b>18</b>. The lower back panel <b>20</b> includes a structural panel <b>20</b><i>a </i>and a cushion <b>20</b><i>b</i>. The bottom panel <b>22</b> includes a structural panel <b>22</b><i>a </i>and a cushion <b>22</b><i>b</i>. The cushions can be made of any suitable material for providing padded comfort to the occupant. Examples of suitable materials include foam, gels, and spring elements. Further examples include a urethane foam with a hardened coating on surfaces adjacent to an occupant to help absorb force during driving. Alternatively, dual density foams and viscoelastic foams (memory foam) may be used. Viscoelastic foam is generally a velocity dependent foam having a desirable energy absorbing quality such that it has a relatively large damping effect with a reduced rebound effect. Preferably, the cushions are covered with an outer trim material made of any suitable conventional trim material, such as cloth, vinyl, or leather.

P-0020[0020] The structural panels provide the structural integrity of the support structures and can be made of any suitable material, such as plastic, fibrous composites, or metal. It is noted that the structural panels need not be as rigid or strong as the spine <b>14</b> since most of the relatively high forces, such as during an impact situation, are generally directed in the longitudinal or fore and aft direction and will be transmitted and absorbed by the spine <b>14</b>. Thus, the support structures may bend or flex by a greater amount compared to the spine <b>14</b>.

P-0021[0021] It is anticipated that the panels <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b> can be releasably attached to the spine <b>14</b>, thereby permitting a consumer to change or replace the panels <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b> with different styled, colored, textured, or dimensioned panels. Thus, with a common mounting assembly <b>12</b> and spine <b>14</b>, a multitude of seat assemblies can be formed by simply replacing the support structures. It is also contemplated that different sized panels <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b> can be used to form the seat. For example, the same spine <b>14</b> and mounting assembly <b>12</b> could be sold to consumers with the vehicle or independent from the sale of the vehicle with a selection of small, medium, and large panels which correspond to an occupant's size. Thus, the seat assembly <b>10</b> can be generally custom fit for the particular consumer. The support structures could also be made of a material which is form fitted to the occupant. Additionally, with the use of replaceable support structures having different right and left panels, a consumer can adjust the characteristics of one side of the seat relative to the opposite side of the seat. For example, in a race situation wherein the vehicle is traveling in the same general direction for an extended period of time, it may be desirable to have different left and right characteristics such as, for example, one side of the seat may need to absorb a greater force than the other. Therefore, the occupant of the seat may want to increase the support or have a seat with specific characteristics on one side of the seat versus the other. Alternatively, a consumer may wish for opposite sides of the seat to have different colors or shapes for aesthetic reasons.

P-0022[0022] The support structures can be releasably attached to the spine <b>14</b> by any suitable manner, such as by threaded fasteners, ¼ turn fasteners, or other quick release-type fasteners. A fastener <b>75</b> is schematically shown in FIG. 4 attaching the headrest panel <b>16</b> to the upper portion <b>24</b> of the spine <b>14</b> via apertures formed in the headrest panel <b>16</b> and the spine <b>14</b>. The structural panel <b>16</b><i>a </i>of the headrest panel <b>16</b> could include recesses or ridges formed therein for preventing rotation or movement of the headrest panel <b>16</b> relative to the spine <b>14</b>. If desired, the cushions could be releasably attached to the structural panels, such as by hook and loop fasteners, to quickly and easily interchange just the cushions to achieve a different style seat. Although the support structures are shown attached to a front surface of the spine <b>14</b>, the support structures can be attached in any manner. For example, the spine could be disposed through the cushion or the structural panel of the support structure. Alternatively, the support structure can be mounted on a rear surface of the spine <b>14</b>, such that the spine <b>14</b> is disposed between the cushion and the structural panel. The structural panels may also be formed with a recess such that the rear or front surfaces of the structural panel and the spine <b>14</b> are flush with one another.

P-0023[0023] One of the advantages of the seat assembly <b>10</b> is that the seat assembly can be relatively light and less bulky compared to conventional seats. As best shown in FIG. 4, the spine <b>14</b> has a lateral width W which is less than the total lateral widths of any of the panels <b>16</b>, <b>18</b>, <b>20</b>, and <b>22</b>. Thus, the lateral edges of the support structures laterally extend beyond the lateral edges of the spine <b>14</b>. The relatively thin spine <b>14</b> generally provides most of the structural strength of the seat when acted upon by longitudinal forces, and the support structures generally provide contoured and lateral support for the occupant.

P-0024[0024] As best shown in FIGS. 3 and 4, the lower portion <b>26</b> of the spine <b>14</b> is generally concave in shape and includes a front portion <b>80</b> and a rear portion <b>82</b> extending from a generally horizontal intermediate portion <b>84</b>. The front portion <b>80</b> extends forwardly and upwardly from the intermediate portion <b>84</b>. The rear portion <b>82</b> extends rearwardly and upwardly from the intermediate portion <b>84</b>. The front portion <b>80</b> provides forward longitudinal support for the legs and hips of the occupant to help prevent the occupant from sliding forward during an impact situation which may occur during a rapid deceleration event such as in an impact or sudden deceleration. The upwardly extending front portion <b>80</b> generally provides a vertical component in a generally horizontally shaped seat bottom to assist in retaining the occupant subjected to a generally horizontal force. The spine <b>14</b> can be suitably formed from a single continuous curved structure which provides both back and bottom support for the occupant.

P-0025[0025] If the seat assembly <b>10</b> is configured to include interchangeably support structures, it is preferred that the vehicle have a control system that alerts the driver if one or more of the support structures are not installed or not properly installed. This can be accomplished by a controller <b>90</b> in communication with one or more sensors <b>92</b>. The sensors <b>92</b> detect a missing or misaligned panel. If a panel is not installed properly, the sensor <b>92</b> transmits a corresponding signal to the controller <b>90</b>. The controller <b>90</b> can alert the driver, such as by an audible, tactile, or visual feedback device, that one or more of the panels is incorrectly installed. Alternatively or additionally, the controller <b>90</b> can prevent the vehicle from starting such as by interrupting an electrical power supply to the vehicle's ignition system. Such a sensor system is preferably in the form of having the support structures including a radio frequency emitter (although a hard wired connection can be used) within the sensor. The controller <b>90</b> would detect signals from the emitters. It is preferred that a RF system is used such that wiring is not required from each seat panel to the controller. It can be appreciated that this aspect of the invention can be performed by any suitable means.

P-0026[0026] The seat assembly <b>10</b> may also include a passenger restraint system having one or more straps or belts <b>100</b>. The belts <b>100</b> have an end which is retractable from a conventional spooling seat belt retractor <b>102</b> and attached to the mounting assembly <b>12</b>. The retractor <b>102</b> is mounted on the rear portion of the mounting assembly <b>12</b>. A pair of notches <b>104</b> may be formed in the lower back panel <b>20</b> to help guide the belts <b>100</b> about the hip region of the occupant. The belts <b>100</b> extend through the respective notches <b>104</b>. Additional shoulder guides <b>106</b> may be attached to the upper back panel <b>18</b> to guide the belts <b>100</b> about the shoulders of the occupant. It should be appreciated that a passenger restraint system can be implemented with the seat assembly <b>10</b> without having notches formed in the support structures. The illustrated restraint system is shown as being an all-belts-to-seat arrangement, however it should be understood that the belts can also be attached to the vehicle body as is well known in the art. Also, any suitable restraint arrangement, such as a three, four, or five point restraint system may be incorporated.

P-0027[0027] In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.