LOAD RESPONSIVE SEAT/BED
A support section for a seat (2) comprises a load responsive framework wholly or partially enclosed in amorphous upholstery, the frame work comprising multiple independently operable load responsive sub systems which collectively permit the support section to respond and react to local areas of loading whereby to provide superior support and comfort to the seat occupant. The support section may be embodied as the whole or a part of; a seat back rest and/or a seat base.
The present invention relates to seating, for example but without limitation; motor vehicle seating, salon seating, seats or adjustable beds for medical and dental examination, office seating, child safety seating, lounge seating, gaming chairs and hospital beds. More particularly, the invention provides a modular system for providing a load responsive seat/bed which provides a user with improved comfort and safety when positioned in the seat or bed.
For simplicity, the term “seat” as used herein should be construed to include the wide range of seating and bedding referred to above.
Modular seats are known, for example in the automotive industry. Predominately automotive seats are constructed in individual sections, these being a frame element and a cushion element. It is clear that the frame and cushion elements in the prior art are not considered integral with each other. Numerous examples from the prior art can be drawn upon to illustrate such. Jackson (US2006125304) illustrates a cushion element which is able to be incorporated into a frame element and as such Jackson does not provide an integral solution.
Steele et at (WO03018353) shows a frame element with a focus on the ability to fold. Steele et al illustrates the seat frame has been considered separate to that of the cushion element and in terms of non-integration is similar Jackson. This philosophy is again demonstrated with SIEGEL et al (DE10358720) where the focus is again on a folding frame element as opposed to an integrated solution which also considers a cushion element as an integral feature to form an entire seat.
The non integration illustrated by the prior art typically results in excessive seat dimensions where the overall seat takes up a large amount of space in a vehicle as the two elements are considered separately. This is further demonstrated by Jackson where the traditional focus on frames independently of comfort results in the requirement for an additional unit to assist the user in seat adjustment.
Particularly in the automotive sector, the requirement for thin and low weight seating that is also comfortable to the user is increasingly of paramount concern. For example the dimensions of the seat dictate the cabin space and consequently the permissible shape, occupancy space, size and weight of the vehicle and thus the aerodynamics and overall the fuel efficiency of the vehicle.
The present invention seeks to address this problem by providing an integrated seat design where the frame element and user comfort are considered and resolved in a single compact and lightweight construction.
The present invention further seeks to provide modular seat sections which are actively responsive to loading and which can be embodied in a compact and lightweight construction.
In accordance with the present invention there is provided a support section for a seat comprising a load responsive framework wholly or partially enclosed in amorphous upholstery, the frame work comprising multiple independently operable load responsive sub systems which collectively permit the support section to respond and react to local areas of loading whereby to provide superior support and comfort to the seat occupant.
The support section may be embodied as the whole or a part of; a seat back rest and/or a seat base.
A seat in accordance with the invention may comprise an integrated back rest and seat base, the back rest and seat base both including one or more support sections.
The upholstery may comprise one or more materials selected from: an energy absorbent material, a contained fluid and a foam. A plurality of different materials may be laminated to provide the upholstery. For example, the laminate may comprise; an outer cover layer enclosing at least one foam layer, and a fluid/gel filled layer. A fluid/gel filled layer optionally comprises two or more sections in fluid communication controlled by one or more valves permitting the redistribution of the fluid/gel between the sections when any one or more sections is under load. Optionally the valve or valves are configured to have a different opening pressure requirement for each of the directions of travel of fluid between any two sections.
A foam layer may comprise a foam which is a high density foam or a foam which is fire retardant.
The enclosed layers may be pressurised. The contained fluid is optionally at least partly gaseous and may, for example comprise oxygen.
Desirably, the cover layer is configured to have a low friction surface on the surface which interfaces with the enclosed layers.
One or more of the sub systems desirably comprises a position adjustment mechanism comprising a drive arranged to drive a leadscrew in rotation about the leadscrew's central axis; a toothed drive meshing with the leadscrew, rotation of the leadscrew causing linear motion of the toothed drive; the toothed drive independently meshed with a first gear wheel, linear motion of the toothed drive causing rotation of the first gear wheel; a second gear wheel meshed with the first gear wheel, rotation of the first gear wheel in a first direction causing rotation of the second gear wheel in an opposite direction; the second gear wheel meshing with a toothed rack, the toothed rack arranged in parallel alignment with the toothed drive and rotatably mounted to permit rotational movement about the linear axis of the toothed rack, rotation of the second gear wheel resulting in linear travel of the first and second gear wheels and toothed drive along the length of the toothed rack.
The mechanism optionally further includes a third gear wheel which meshes with the toothed rack and whilst free to rotate is fixed in position relative to the second gear wheel. The three gear wheels are desirably contained in a casing, the casing adapted not to restrict the linear motion of the gear wheel system relative to the toothed rack.
Optionally, rotation of the toothed rack is countered by a biasing mechanism.
Conveniently two mechanisms of the invention can be connected by a load responsive linkage which transmits changes in the applied load to one or both mechanisms whereby to adjust the linear position of the gear wheels and toothed drive.
Desirably the load responsive linkage is responsive to asymmetric loading to adjust the position of each position adjustment mechanism independently of the other. The load responsive linkage conveniently comprises a resiliently deformable material. In specific embodiments the load responsive linkage might comprise at least in part of a plate or bar of flexible material incorporating a plurality of cut out channels which, under load can be caused to close under compression or open under tension. Optionally the load responsive linkage comprises at least in part of a spring.
In one particularly useful application, the linked pair of mechanisms is embodied in a support frame for a seat, the support frame comprising a pair of support members arranged substantially in parallel with the toothed rack and cross plate members extending between the support members, the support members and cross plate members together enclosing the paired mechanisms. Desirably the cross plate members are comprised at least in part of a resiliently deformable material.
Preferably the support members are fixed in position and the cross plates are flexibly linked to the support members. The flexible link is desirably a resiliently deformable link which enables the plate members to return to a neutral position with respect to the support members when the apparatus is not under load.
In a preferred embodiment, the cross plate members are enclosed in a flexible covering, the covering having a low friction surface slidably interactible with the cross plate members. Desirably, a cushioned upholstery layer encloses the flexible layer.
The support frame is usefully employed as a back rest for a car seat.
The back rest is conveniently linked to a seat base by at least one gear mechanism configured to enable adjustment of the angle between the plane of the back rest and the plane of the seat base. In one embodiment, the gear mechanism comprises an actuator configured to actuate a first bevel gear, the first bevel gear meshing with a second bevel gear oriented in a substantially orthogonal plane to that of the first bevel gear; the second bevel gear operating a leadscrew carrying a toothed drive nut, the toothed drive nut configured to move linearly along the leadscrew as the second bevel gear rotates; a third gear meshing with the teeth of the toothed drive nut and operable to tilt the leadscrew relative to an exit shaft rotatably mounted in the seat base whereby to tilt the seat back relative to the seat base.
In a preferred embodiment, the third gear is linked to the exit shaft by means of a chain of additional interengaging gears, the last gear in the chain being fixedly mounted to the exit shaft.
The means of connection between the backrest and seat base portions is not essential to the invention and may comprise any of a permanently fixed, detachably fixed and/or movable connection. In the presently described embodiment, the seat and the backrest are moveably connected, for example pivotally connected, whereby the backrest is movable relative to the seat in a rotational manner allowing the backrest to be tilted. The rotational motion of the backrest is facilitated by at least one rotary actuator that can be located largely within the seat or the backrest, alternatively the actuator can be located externally.
The or each rotary actuator may be configured to enable the backrest to rotate about at least one axis. The backrest and/or seat optionally further include at least one linear actuator. The or each linear actuator is employable to increase or decrease the linear separation between the backrest and the seat for example (but without limitation) by moving the seat forwards or backwards independently of the back rest, or the backrest up and down independently of the seat portion. Thus the modular integrated seat can be configured to enable both rotational and linear movement of the seat relative to the backrest and/or of the backrest relative to the seat.
The linear and rotary actuators provided in the seat and/or backrest may be arranged to operate simultaneously allowing the backrest and/or the seat to move in a combination of linear and/or rotary motion with respect to each other. Any combination of linear and rotary actuator may be incorporated into or associated with either or both of the backrest and seat.
Furthermore, a linear actuator having a first linear axis may be located generally towards one side of the backrest or seat and another having a second linear axis generally towards the opposite side of the backrest or seat, each linear actuator being operable to cause linear motion along its own axis independently of the other. The linear actuators can be pivotally mounted at one or both ends. With this arrangement, the backrest or seat is able to be moved generally along the first or second axis depending on which linear actuator is being operated and/or the relative speeds of each linear actuator.
The integrated seat may be connected with a support structure, for example but without limitation a vehicle body or support frame for a seat. The nature of the connection is not essential to the invention and may comprise any of a permanently fixed, detachably fixed and/or movable connection. The connection might be made directly between either or both of the back rest and seat portion. The integrated seat may also have associated therewith at least one operating mechanism operable to allow the integrated seat to move linearly and/or rotationally. Again, the nature of the connection of the operating mechanism with the seat is not essential to the invention and may comprise any of a permanently fixed, detachably fixed and/or movable connection.
The operating mechanism may be permanently fixed, detachably fixed and/or movably attached to at least one support structure, for example but without limitation a vehicle body or frame or mount. The integrated seat is able to be attached to both a suitable operating mechanism and the at least one support structure.
Suitable operating mechanisms are known in the prior art and it is within the ability of the skilled addressee to adapt these for use in accordance with the invention. Various examples of operating mechanisms providing singular movements or combinations of movements are available in the prior art. One simple and useful example (without limitation) from the automotive industry is runners which are commonly used to move a vehicle seat linearly fore and aft. Mechanisms facilitating the tilt of a back rest relative to the seat or seat relative to a base; the position of a lumbar support portion of a back rest and the up down motion of both back rests and seat portions are also known.
The seat is desirably provided with at least one or more operating mechanisms configured to enable the integrated seat and/or the backrest and/or seat portion to move in a wide range of dimensions some or all of which are selected from; linearly fore and aft; linearly up and down; rotationally pitch and roll (to enable tilt from side to side or front to back) and/or yaw. The configuration may be arranged to permit any combination of these movements to be performed simultaneously or independently.
The operating mechanism(s) may conveniently be embodied as a link between the seat and backrest portions allowing the singular or combination of movements to be translated to one or both of the backrest or seat portion allowing the portions to be repositioned relative to each other as well as repositioning of the entire integrated seat in one adjustment. The seat and/or back rest portion might optionally be disengageable from the operating mechanism so as to enable independent movement of the seat or back rest portion.
Optionally, the backrest is mounted directly to a support structure by means of an operating mechanism and is able to undergo rotational and/or linear movement. Therefore the backrest is able to be attached to the support structure with the seat then attached to the backrest. Alternatively, the seat is able to be attached to the support structure. In another option both the seat and back rest are directly attached to the support structure.
The support structure may feature at least one actuator which may be rotary, linear or a combination of the two. A rotary actuator desirably includes an output shaft able to form in whole or in part an attachment element to which the backrest and/or the seat portion and/or integrated seat may be linked. The link may be anything from (without limitation) a fixed connection, a pivotal connection, a slidable connection and/or detachable link. The output shaft may, optionally, provide two attachment elements, the first being attachable to the seat and the second to the backrest.
Each of multiple support structures might include one or more actuators which are linear or rotary in any combination. Desirably, rotary actuators are arranged coaxially and share an axis of rotation with the attachment elements. In this arrangement, when the at least one rotary actuator largely within a support structure rotates then the backrest and/or seat rotate.
Where a linear actuator is also incorporated with the support structure then the linear actuator and the rotary actuator can be operated simultaneously or independently. Where two or more support structures are present with each member having at least one linear actuator, it is preferred that the linear actuator in each member can act at different speeds and/or at different times. Typically but not limited to the linear actuators are able to feature a suitable pivot point at each end. Pivot points are well known in the prior art and include (without limitation) a rose type rod end joint or other such multiple axes coupling or joint.
Desirably the seat is configured to have at least one rotary actuator wholly or partially embodied in the seat portion and at least one linear actuator wholly or partially embodied the back portion.
Output shafts of rotary actuators in the seat or backrest portion may conveniently be arranged coaxially with output shafts of rotary actuators in the other of the back rest or seat portion. An output shaft from a rotary actuator associated with the seat is optionally attached to the first attachment element of the output shaft of a rotary actuator associated with the support structure; a rotary actuator in the backrest may be attached to the second attachment element of the output shaft of the rotary actuator associated with the support structure. As previously described, all connections are optionally permanently fixed, detachably fixed and/or movable connections.
In the above described arrangement, a rotary actuator in the seat and/or backrest may be configured to counter rotate the motion or to rotate in the same direction to the motion of the rotary input of a rotary actuator of the at least one support structure. This enables configurations where; the backrest and the seat can rotate independently of each other and the input of the rotary actuator of the support structure; or move in combined movement with the input of the rotary actuator.
The ability for the seat and/or backrest to counter rotate allows the seat and/or the backrest to rotate independently and allows each to maintain a position irrespective of the rotation of the rotary output shaft or shafts of the rotary actuator of the support structure.
In another alternative, a linear actuator may be wholly or partly embodied in a support structure, a seat portion and/or a backrest portion. The multiple linear actuators associated with the seat, backrest and support structures may be configured to extend and retract independently, in unison, or in groups. For example, sections of the integrated seat may comprise multiple linear actuators which can work in unison as a group, but independently of other actuators or groups of actuators in different sections.
Optionally, the integrated seat may incorporate one or more airbags. The air bag(s) may optionally be incorporated in any of or any combination of the backrest, seat or support structure.
As mentioned, backrest and/or seat portion may comprise multiple sections for example (but without limitation), these sections might include a head rest, a lumbar support, a buttock support and a thigh support.
The previously described attachment elements may comprise a range of different configurations sizes and/or lengths. Most conveniently (but without limitation) they collectively comprise a variety of differing diameters and differing lengths.
The differing lengths and diameters allow the seat and backrest to be attached to the elements. This attachment arrangement of rotary actuators of the seat and/or backrest portions to the output shaft achieves independent rotational movement of the portions counter to or congruent with the rotation of the output shaft and the element. Therefore, the at least one output shaft is able to rotate via the rotation of a transmission path which includes but is not limited to at least one leadscrew and at least one gear or toothed shaft.
The use of a leadscrew allows the rotary actuator to be self locking in that it will hold a position without the requirement for continual power. It will also be appreciated that the casing and/or at least one gear, or shaft, or the saddle is able to be incorporated and able to interact with at least one stored energy system. The stored energy system could comprise any of a number of configurations, for example (but without limitation) includes springs.
The Applicant's co-pending international patent application number PCT GB2010/000250 illustrates the use of springs in a stored energy system which could be incorporated into seats made in accordance with the present invention. As an example, the rotary actuator might incorporate at least one mechanical or other type of spring whereby movement in a first direction allows energy to be recovered and stored for use (deployment) in a second direction. The arrangement can be configured to enable recovery, storage and deployment at any point or a desired pattern of points in the movement cycle of the rotary actuator. Such an arrangement is enabled to be self locking as well as store energy from one direction for that energy to be deployed in the opposite direction.
A support section may be linked to another body, the link being configured to permit movement relative to the body in any one or more of three orthogonal linear dimensions, a first dimension being parallel to the plane of the body. Furthermore, a support section may be linked to another body, the link being configured to permit rotational movement relative to the body about any one or more of three orthogonal axes, a first axis being parallel to the plane of the body.
Conveniently, the body is another support section optionally associated with a different seat section. Alternatively, the body is a support structure independent of a seat or backrest in which the support section is embodied; for example but without limitation; the support structure is selected from; a vehicle body, a mounting frame or a seat portion not embodying a support section as previously described.
The link conveniently comprises at least one rotary actuator configured to enable adjustment of the angle between the plane of the back rest or seat base and the plane of the body. Examples of suitable rotary actuators are further detailed herein.
One example of a rotary actuator comprises a gear box having an actuator configured to actuate a first bevel gear, the first bevel gear meshing with a second bevel gear oriented in a substantially orthogonal plane to that of the first bevel gear; the second gear operating a leadscrew carrying a toothed drive nut, the toothed drive nut configured to move linearly along the leadscrew as the second bevel gear rotates; a third gear meshing with the teeth of the toothed drive nut and operable to tilt the leadscrew relative to an exit shaft rotatably mounted in the body. The third gear conveniently may be linked to the exit shaft by means of a chain of additional interengaging gears, the last gear in the chain being fixedly mounted to the exit shaft.
In a further example the exit shaft of the rotary actuator serves as part of the drive mechanism for the already described linear position adjustment mechanism.
The rotary actuator optionally incorporates a resilient means which serves to store energy when the rotary actuator rotates in a first section and to release energy when the rotary actuator rotates in an opposite direction to the first direction. Without limitation, the means may comprise a mechanical spring.
A linear actuator for moving the section optionally is comprised of; drive means for driving a drive column in a rotational motion, a leadscrew configured to rotate as the drive column rotates, a piston rod axially aligned and meshing with the leadscrew thread and means for holding the piston rod in a fixed rotational position relative to the axis of the leadscrew whereby axial rotation of one of the leadscrew and piston rod relative to the other of the leadscrew and piston rod results in adjustment of the relative positions of the piston rod and leadscrew along the axis of the leadscrew. The means for holding the piston rod in the fixed position conveniently may comprises at least one longitudinal recess in the drive column into which slidably engages at least one circumferentially extending protrusion of the piston.
The piston rod is desirably but not essentially slidably mounted through a first gear driven by a motor, the first gear meshing with a second gear fixed to the drive column whereby on actuation of the motor, the drive column is caused to rotate and rotates the leadscrew. In another useful but not essential option, the linear actuator includes a mounting aperture rotatably mountable on a shaft. The mounting aperture may conveniently be mounted on the exit shaft of a rotary actuator.
Preferably, the frame work incorporates one or more apertures through which conditioned air can be delivered to the seat from within the seat. Desirably the seat will further incorporate a manifold and ducting connecting with the aperture, the ducting also connecting with an air conditioning system located externally of the seat, for example within a car body in which the seat is mounted. Most desirably, there are provided multiple apertures and a branched system of ducting delivering conditioned air to each of the multiple of apertures. In addition, one or more fans may be provided within the ducting to facilitate the drawing and circulation of the conditioned air to the seat.
The framework may comprise support members connected by one or more cross plate members, the linkage between the cross plate member and support member being comprised of a collar portion of the cross plate member encircling a pole of the support member, the pole and collar being rotatably linked by a bearing. Desirably the collar portion includes a low friction cover on its outermost surface. Also desirably the pole is hollow allowing for the circulation of fluids and/or conditioned air through the seat.
Optionally the hollow pole further includes ribs to strengthen the support structure.
A seat or seat section in accordance with the invention desirably includes adjustment means for adjusting the stiffness of the section and/or load range within which section responds.
A seat base embodying the invention optionally has a framework comprising support members connected by one or more cross plate members, upholstery is provided on an outer facing surface of the cross plate member(s) and a sprung plate is resiliently biased against the inner facing surface of the cross plate member(s). The seat base will optionally further include at least one mechanism for adjusting the height and/or orientation of the seat base, the mechanism being enclosed by the frame work and a transfer board for transferring loads applied by the mechanism to the cross plate member via the sprung plate. Desirably the mechanism is a dual purpose lift and tilt mechanism.
Conveniently, the mechanism can comprise a lifting cam.
The sprung plate can conveniently comprise an arcuate section of resiliently deformable material anchored to the support members.
A seat comprising one or more support sections may further include a locking mechanism for locking one or more components of the seat in position.
In one preferred embodiment, the lock comprises; a leadscrew mounted in bearings, the leadscrew driven by an actuator and meshing with a toothed drive rack, the toothed drive rack carrying in a locking pin which on actuation of the leadscrew is caused to move axially along the leadscrew axis whereby to engage or disengage with a component to be locked or unlocked.
In an alternative desirable embodiment, the lock comprises; a leadscrew mounted in bearings, the leadscrew driven by an actuator and meshing with a screw threaded collar, the collar carrying multiple locking pins which on actuation of the leadscrew are caused to move axially along the leadscrew axis whereby to engage or disengage with one or more components to be locked or unlocked.
The locking mechanism may conveniently be used to lock the back rest to the seat base.
By suitable choice of material and adjustment of the parameters of the described connecting and actuating components a seat constructed of the modular seat support sections as described and interconnected as described can be configured to provide optimum comfort and support to the user as well as increased protection in reaction to a sudden and unexpected change in loading conditions on the seat, incurred, for example, when a vehicle in which the seat is employed is involved in a collision.
Furthermore, the integrated seat construction as described in accordance with the invention permits the realisation of an ultra thin seat which in turn yields increased cabin space and reduced vehicle weight which in turn allows more flexibility in the optimisation of the design of the exterior of a vehicle as well as facilitating an overall reduction in the vehicles overall size if required. Benefits of this added flexibility to the design of the vehicle enables a vehicle to be optimised not only to reduce the pollution generated by the vehicle (and consequent environmental damage) when the vehicle is used, but also environmental pollution that would otherwise be generated during the industrial scale manufacture and distribution of vehicles compared to prior known vehicle designs.
Some embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:
The actuator 8 is able to be at any angle and it is able to be attached directly to the leadscrew 34 without the requirement for any gears. Alternatively (and as shown) the actuator 8 can be connected to the leadscrew 34 by at least one gear. Where more than one gear is employed, they are able to be of different sizes. The gear 12 is also able to be integrated with the leadscrew 34. Meshed with the leadscrew 34 is a toothed saddle 32, where the toothed saddle is further meshed with the toothed end shaft 30 such that rotation of the leadscrew moves the saddle 32 along its axis in the first or second direction depending on the rotational direction of the motor 8. Linear motion of the saddle is translated to rotational motion of the shaft 30 by the meshed relationship between the saddle 32 and the shaft 30. The shaft 30 is attached or integrated with the gear 14 where the shaft 30 and gear 14 are held rotationally free in the casing via at least one bearing 28 and 16.
The gear 14 is in this case (but without limitation) arranged to mesh with gear 22. Gear 22 is integrated with or attached to the shaft 18 and held in a fixed position in the casing but is free to rotate by means of bearings 20 and 24. As the motor 8 rotates and the toothed saddle 32 moves linearly as described above, the consequent rotation of the shaft 30 rotates the gear 14 and through its meshed relationship with gear 22 also rotates gear 22 which in turn rotates the output shaft 18.
The output shaft 18 is able to be an extension to the toothed shaft 30. In such an embodiment (not illustrated) the rotary actuator would function as has been described above, yet feature two output shafts; the rotation of the actuator 8 via a leadscrew and toothed shaft and/or a gear would rotate the output shaft 18 as well as the output shaft extension to the shaft 30. It will be appreciated that the shafts 30 and 18 would rotate in opposite directions but this is able to be addressed with the inclusion of a further gear in a meshed arrangement with and between gears 14 and 22. In this case, both shafts 30, 18 would be self locking.
In an alternative embodiment, the rotary actuator 8 in
The at least one output shaft 18 of the rotary actuator 6 has two attachment elements, a first attachment element 124 and second attachment element 122 (as can be seen in
The output shaft 18 is able to rotate through a transmission path which in this case comprises (but is not to limited to) a leadscrew and at least one gear or toothed shaft. The use of a leadscrew allows the rotary actuator 6 to be self locking in that it will hold a position without the requirement for continual power. As detailed above, the casing 36 and/or gear(s), shaft(s) or saddle 32 may be arranged to incorporate and/or interact with a stored energy system which, for example, comprises substantially of springs.
The rotary actuator 40 has a casing 54 which allows the retention of components therein and operation of one or more gears, toothed shafts and/or leadscrews as previously described for the first embodiment. The actuator 40 typically is driven by a motor 64, for example an electric motor, but alternatively may be a manual system. The actuator 64 incorporates a gearbox 68 which attached (fixedly or detachably) to the motor 64. The gearbox 68 has an output shaft to which is engaged with a gear 70.
The gear 70 meshes with gear 72 and rotation of the motor 64 results in rotation of the gearbox 68 and the rotation of the gears 70 and 72. The gear 72 engages with the leadscrew 62 where the leadscrew 62 can be held within the casing via a bearing or bearings 60. The leadscrew is meshed with the tooth saddle 66 which engages with the saddle spur 58. Rotation of the motor 64 rotates the leadscrew 62 via its relation to the gear 72 causing the saddle 66 and spur 58 to move linearly along the length of the lead screw 62.
The spur 58 meshes with the gear 56 which engages with the shaft 76 located on a bearing or bearings 74. The gear 56 meshes with the gear 50 which engages with the shaft 78 located on a bearing or bearings 52. All bearings are held by and or within the casing 54. The casing 54 features a gap 48 between the gears 50 and 44, the gap is used to place a rotationally mounted toothed rack such as 170, 154, 136 or 182 through which meshes with the gears 50 and 44. An example of the at least one toothed rack 154 can be seen in
The toothed rack can be configured to include double side gear teeth which mesh with the gears 50 and 44. Gear 44 engages with the shaft 42 which is located on a bearing or bearings 46. Therefore, as the motor 64 rotates and moves the saddle 66 and spur 58 linearly along the axis of the leadscrew 62, the saddle 66 via its meshed relationship with the gear 56 rotates gear 56 which in turn rotates gear 50. As gear 50 rotates it and the casing 54 will move linearly along the axis of the toothed rack 154. The gear 44 via its meshed relationship with the toothed rack 154 will rotate as the casing 54 moves linearly along the axis of the toothed rack 154 and via the relationship between the casing and the gears 50 and 44 the meshed relationship with the tooth rack 154 is maintained.
The casing is engageable with the at least one output shaft of the rotary actuator 6 and can be further adapted to attach fixedly, removably and/or movably to at least one of the attachment elements 122 and 124 (seen in
The linear actuator 80 features a piston rod 106 which is attachable to the integrated seat, optionally by one or both of the seat or the backrest portion. The piston rod 106 is meshed with a leadscrew 82 which is attached or integrated to the drive column 90. The piston has at least one protrusion 88 which in this arrangement engages slot 86 located in an inner drive column 92. The drive column 92 is located on bearing 84. The linear actuator 80 features an electric motor 102 although a manual actuator could also be used. The motor 102 is attached to a gear 104 such that when the actuator 102 rotates, the gear 104 rotates. The gear 104 meshes with a corresponding gear on the drive column 92 and as such the drive column 92 will rotate as a result of the motor 102 rotating.
The rotation of the drive column 92 in turn rotates the leadscrew 82 and via its meshed relationship with the piston 106, the piston 106 extends with the protrusion 88 keeping the piston rod 106 in the correct orientation.
Attachment of the linear actuator can conveniently be achieved with a multi-axis joint such as a rod end.
The mount 126 allows exit shafts (18, 30) to exit at different locations. In a manner as already described above in relation to other shafts, the exit shafts 18, 30 feature attachment elements 124 and 122. In a preferred arrangement, element 124 is larger than element 122. Either attachment element is able to define a bore. Linear actuator 80 is able to be attached to the shaft 18 and an element 124. It is shown that the shaft 18 has two linear actuators 80 and these are able to be connected to the integrated seat or the seat or the backrest as is the actuator 80 shown for the second shaft 30.
The linear actuators allow the seat or integrated seat or backrest to move linearly whilst the rotary actuator allows the linear actuators for move rotationally and thus the seat or the integrated seat or the backrest is able to move with relation to rotational input and linear input of the respective components.
The backrest features a pair of actuators 6. Typically these are rotary actuators and are arranged in coaxial alignment with each other. An actuator includes an exit shaft which allows the rotary actuator to be connected to a seat portion or directly to a support structure such as a vehicle body, frame or mount.
Rotation of one or both actuators 6 rotates the backrest around the associated exit shaft axis, in the case shown, this is the shared axis of the coaxially aligned actuators. As illustrated, the actuators 6 are integrated with a frame 188, 132 of the backrest as described later. As is illustrated the backrest may feature at least one frame per section and at least one section. In one convenient embodiment as shown, the backrest 2 features two frames per section with frames 132 and 188 in the bottom section, and 150 and 166 in the top section.
Operation of rotary actuators 6 rotates at least one section (and desirably all the sections) of the backrest 2 around the exit shaft(s) axis. The rotary actuators 6 as illustrated are able to be connected with each other in a fixed, integrated, detachable and or movable relationship to form a first rotary unit 130. The first rotary unit 130 is connected in a fixed, integrated, detachable and or movable relationship with one or both frames 132 and 188. The rotary unit 130 may be configured to incorporate any or all of the functions and features and configurations as already described for rotary actuator 6. For example, the unit 130 may include multiple exit shafts connected to or integrated with a support structure such; as seat, vehicle body, frame and/or mount.
The frames 132 and 188 are each in operable communication plate 134 which consists of at least one material and incorporates a flexural capacity and/or reaction capacity. Multiple materials may be used each at various regions of the plate and individually providing different flexural capacity and/or reactions in those regions. Desirably two plates 134 are incorporated in a section. Preferred plate configurations 134 are described in more detail later.
A plate 134 incorporates slots 138 and 184 as shown, though the quantity of slots is not essential. The plate 134 further incorporates a low covering 186. Desirably the covering has a low friction surface. Optionally, the covering features a foil or other highly polished surface.
Under the covering is a cross member connected in a fixed, integrated, detachable and or movable relationship with one or more rotary actuator 40. As has been previously described the rotary actuators 40 are able to move linearly along respective toothed racks 136 and 182. As the rotary actuators move linearly in the first and second direction so the cross member to which they are attached moves in the first and second direction.
The connection between the cross member and rotary actuator 40 is preferably a flexible column which locates through the slots 136 and 184 respectively. The cross member is desirably configured to be whether by construction or choice of material or a combination of both. Most desirably the cross member is resiliently flexible, that is it has a neutral form to which it is able to return when not under load.
In the integrated seat, each frame and or section incorporates one more toothed racks.
Most conveniently but without limitation, the toothed rack(s) is rotatably mounted to a frame and able to rotate about its axis. In an exemplary embodiment, at least one bearing is located at each end of the toothed rack to allow low friction rotation. A sprung element is desirably associated with the rotatable mounting and is able to resist or assist the rotation of the toothed rack around its axis. For example, the sprung element could be a mechanical spring (of which many suitable alternatives are known in the prior art and could be selected by the skilled addressee.)
In one suitable arrangement, one end of the spring is captivated in the frame and the other end is attached to the toothed rack. Therefore if the toothed rack rotates from its centre position where no rotational load is exerted on the spring then if the toothed rack moves in the first or second direction then the spring resists the rotation. However if the toothed rack moves in the first or second direction and begins to reposition itself to its neutral, centre position, the spring assists that return rotation of the toothed rack.
Typically the at least one plate 134 is able to flex as referenced above and as further referenced detail will be given later. However and to understand the manner in which the cross member and toothed rack operates some plate operation will be described. Typically but not limited to the at least one cross member 176 (generally toward the lower part of the backrest) serves a lumbar support. This lumbar support will typically receive the primary part the load exerted by an occupant of the seat in which the back rest is incorporated.
In use, as a load is applied the cross member will receive that load and start to flex in a first direction, sharing and transmitting that load with at least one plate and at least one sprung element via the at least one flexible column as described, and consequently the rotary actuator 40.
As a load is applied and generally increases, the at least one plate as part of the assembly including the at least one cross member, the at least one flexible column attaching it to the at least one rotary actuator and the at least one toothed rack and at least one sprung element thereof described above, flexes in the first direction.
The flexing of the plate allows the cross member to flex in the first direction. The flexure of the cross member places a load through the flexible columns which will also flex in the first direction and into the at least one rotary actuator 40. The rotary actuator 40 receives a load via the plate which transmits a load to the actuator casings. The load placed onto the rotary actuator moves the actuator in the first direction applying a rotational force to the toothed racks 136 and or 182. This rotational force will cause the toothed rack(s) to move in the first direction, this motion is resisted by the at least one sprung element.
The combination of components is repeated throughout the back rest in the multiple sections providing a completely sprung backrest system. This provides a backrest which can react to changes in the load applied to the back rest. Furthermore, where the load is not evenly distributed, sections of the backrest respond to local loading rather than an average load on the backrest.
The backrest is conveniently (but not essentially) configured such that an applied load will result in movement of the assembled backrest generally in a first direction whereby to absorb the load, and a responsive load provided by the sprung system incorporated into the backrest movement in a second direction is configured to counter the load with an equal or amplified force which is transmitted back to the in the second direction. Desirably, the backrest sprung system is configured to act (i.e. flex more quickly) in the first direction and slower (i.e. return back to its neutral position) in the second direction. There are various ways of accomplishing this and these will be discussed in more detail later in the discussion that follows.
It will be appreciated that the actuator 40 acts both to assist in the sprung nature of the seat and has to act in facilitating relative rotational movement between components. The actuator 40 is attached to the flexible column which is located through a channel 138. Therefore as the plate moves, the relative position of the rotary actuator and thus flexible column changes with relation to the plate and channel. Therefore, in order that the operation of the rotary actuator 40 results in the linear movement of the cross member, the rotary actuator 40 must be allowed to move relative to the at least one plate. As described, this is facilitated by the incorporation of the toothed rack which has rotational capability and is sprung and serves both to assist the flexure of the plate and in assisting in provision of a reactive load by the backrest sprung system.
The two support structures 120 are coaxially located. Conveniently, the linear actuators in this case are attached to the rotary actuator of the support structure 120 via a rotational attachment element 144. The rotational element 144 allows the rotary actuator to rotate about its axis. It is also clear from the illustration that the rotary actuator 40 utilises a different orientation for the motor of the linear actuator. In this configuration the motor is inline and not at 90 degrees as that which is illustrated in
Rotational element 144 allows the support structure 120 situated above it to pivot relative to the frame. In this case the frame is embodied an upper section. The upper section consists in this case of two frame sections 150 and 166. Therefore the ability of the rotary actuator 40 to pivot about the axis of the rotational attachment element 144 means that the frame section 150 and 166 are able to pivot about the axis of the element 144
The ability of the support structure and frame to pivot relative to each other as described above enables the frame section such as 150, 166 as well as 132 and 188 to flex. This flexibility operates in parallel with the sprung systems already described for the backrest section. The degree of flexure of the frame section can be designed by suitable choice of materials, shapes, etc. For a vehicle car seat, it is appropriate to select materials and design to configure the frame section to flex only in high load situations such as those that might be encountered in a collision at speed. It is within the abilities of the skilled reader to select appropriate materials and adjust design parameters of the inventive concept to adapt the seat for use in a desired loading situation.
The at least one member 120 is partially able to rotate about the at least one element 144 and as such the linear actuator of the member 120 will remain stationary, that is, free from rotation. It is also relevant that the at least one element 144 is able to feature a sprung element that is able to feature all the same functions and features as the sprung element attached to the at least one toothed rack and thus these functions and features will not be repeated. Typically the sprung element and the flexure of the backrest as well as the backrest sprung components combine to provide both comfort and crash protection to the occupant.
In this case and as illustrated the upper backrest section is indicated by the two support structures 120 and the frame sections 166 and 150. When the members operate rotationally the associated upper backrest section rotates around the axis of the support structures 120 in a first and second direction. When the linear actuators operate the section is able to move away or draw closer to the associated lower backrest section represented by the frame sections 132 and 188. Therefore operation of a linear actuator of the support structure 120 is able to move the upper section in the respective first and second linear direction.
The upper backrest section is able to feature all the same functions and features as the described lower backrest section. Whereby all the backrest sprung components such as the plate 156 (134), the channels 160 (138) and 164 (184) and the cross member 162 (176) as well as the toothed racks 154 (136) and 170 (182) and the rotary actuators 40 and cover 148 (186) all operate in the same manner as the same components as described in relation to the lower backrest portion. (For avoidance of doubt the at least one lower backrest sprung components identifiers have been given in brackets in the above text and are of the same name.)
In this case the backrest has two frame sections 132 and 188 and has only one backrest section whereby the frames are continuous. The backrest in this case has two plates 134 and 156. The plates have all the same functions and features as has been highlighted previously for the other back rest section.
Conveniently (but without limitation), the ducting may be provided in a branched arrangement each delivery duct having at least one delivery branch, as shown, the duct 200 has a branch 202 and the duct 204 has a branch 196.
The ducting 210 may be connected to an air conditioning system, for example, the air conditioning system of a motor vehicle in which the seat is situated. The ducting allows conditioned air (heated or cooled and or filtered) to enter the manifold. The manifold in this embodiment consist of an electric motor attached to a cylinder with at least one orifice. The electric motor rotates the cylinder such that an orifice is aligned with at least one of ducts 204, 200.
The ducting 210 is able to be a multiple channel duct and thus able to deliver different types of conditioned air to the manifold such as hot air and cold air. The cylinder receives the multi-channel delivered air and via rotation and alignment of the orifices with the channels and ducts, supplies air to the ducts 200, 204, for example warm air to one duct 200 and cold air to the other duct 204.
Taking ducting 200, the air once delivered will be boosted and or circulated by the fan 192. The fan will assist in the air being drawn up the ducting and then distributed through branch duct(s) 202 where it will exit via the apertures. Once the air exits the holes it will enter the cushion materials and defuse such that the occupant is heated or cooled in at least one region. In this case the at least one region is the upper plate 156, however each plate is able to feature multiple regions and typically each plate will feature at least two regions. Each region via the manifold and channel ducting such as 200 and 204 is able to receive differently conditioned (eg, warm or cool; scented, humidified, filtered) air. For example, the air in one region may be heated and scented, the air in another cooled with particles removed such as pollen.
The same is true of second duct 204. The air once delivered will be boosted and or circulated by the fan 194. The fan will assist in the air being drawn up the ducting and then distributed through branch duct 196 where will exit via the apertures.
Once the air exits the holes it will enter the cushion materials and defuse such that the occupant is heated or cooled in at least one region. In this case the region is the lower plate 134.
The ducting 200 and 204 as well as the branching 196 and 202 desirably comprises a flexible material, for example a variant of rubber. The ducting and the branch is attached to a plate, for example via a bonding agent such as an adhesive. The backrest may include a heater element 208 and this is able to be attached to the plate or to be integrated within the fabric coverings of the backrest and or within the cushioning materials. It is further apparent that the fans 192 and 196 are able to operate without the influx of air or conditioned air via the manifold 212. In this case the ducting 200 and 204 is able to be left open and not closed by the manifold 212 and ducting 210 and therefore when the fans operate, they will circulate air around the ducting 200 and 204 drawn in at the ambient room or in vehicle air temperature. In the case of a vehicle, an air duct from the vehicle is able to be placed near the opening to the ducting 200 and 204 such that the operation of the fan will draw in air circulating in the vehicle.
The plan view shows the plate with a sprung section. The plate shown has four sprung sections 220A, 220B, 222A and 222B. These sprung sections are typically shaped sections and typically but not limited to will be a V type shape, but any suitable shape will be acceptable.
The view also shows the rotary actuators 40 described earlier. A first connection has already been described in relation to the rotary actuator. In addition, a second connection can be used, the second connection attached (again the mode of attachment is not limited). In this embodiment, the second connection 224 is attached to both rotary actuators 40 and is a sprung connection. The material of the connection can be selected to respond (i.e. flex) only to predetermined loading situations.
The connection 224 connects with the blocks 226A and 226B, the material of which is again selected to respond (i.e. flex) only to predetermined loading situations. In this case but without limitation, the blocks will be a form of rubber. Typically the connection 224 passes through the blocks 226A and 226B. Duct 200 as described above, is also illustrated with branch 202.
It will be apparent to someone skilled in the art that the connection 224 is able to cross the ducting without entering the ducting and therefore the ducting is able to be in one continuous piece with or without a branch such as 202. Desirably, the ducting has a shaped section which in this example (but without limitation) is formed similar to an “n” section, this allows the connection 224 to pass through the effective path of the ducting without entering the ducting.
The backrest is desirably covered in one or more layers of upholstery. The layers may comprise any combination of materials with characteristics selected from; cushioning; energy absorbency and deformabilty. An outermost fabric layer provides aesthetic appearance and comfort on touch. In this case the section of the backrest has an outer fabric 242 which typically surrounds the entire backrest. Underneath the outer fabric is at least one foam layer 214 and a confined fluid (for example gel filled) layer 216, finally in this embodiment, a layer of high density foam 218 is also provided.
In a preferred example, gel is in a sealed unit, the sealed unit enclosing at least one section. The sealed unit may contain one or more valve or valve like elements. The valve like element of a first section is able to allow gel or other fluid to move into at least one other second section depending on the amount of pressure applied to that first section. Typically but not limited to each section is able to feature at least one valve or valve like element that is able to open in a first direction and or at least one valve or valve like element that is able to open in a second direction and or at least one valve or valve like element that is able to open in a first or second direction.
Typically but not limited to the at least one valve or valve element in the at least one section is able to have a different opening pressure requirement in the first and or second direction. Typically but not limited to at least one first valve or valve element is able to have a different opening pressure requirement in the first and or second direction to that of a second at least one valve or valve element in the same at least one section.
Around the outer of the plate collar 240 is typically an over cover 244, this is to allow a low friction surface against the inner of the fabric cover 242 and prevent any lubricates from touching the fabric. The at least one frame section and in this case but not limited to 132 is able to feature several internal components that are able to assist the at least one frame section with strength and or designed in flexure and or other features and functions such as ventilation and or wiring looms and or other such aspects. This represents internal multi-usage layout allows the frame to be as compact and space efficient as possible.
In this case but not limited to three different internal components are illustrated, the first is the top centre unit 232. The top centre unit is located at the top and bottom of the internal space and integrates or attaches the frame permanently or removably to the ribs 234 and 230 and typically but not limited two ribs 230 are used either side of the rib 234. Typically but not limited to the centre components are permanently or removably attached and or integrated to each other. The connection provided by the component 232 allows forces to be transmitted effectively to the at least one ribs 234 and 230. The ribs are then able to add strength to the frame and or as stated be designed such that the frame is allowed to flex under certain conditions and or loads and in certain directions against those loads.
The channels created by the at least one rib and the top centre component 230, 234 and 232 respectively allow for compressible or incompressible fluid, conditioned or otherwise, to be distributed through the frame, this can be used for many different applications. Typically conditioned air is distributed throughout the frame and exits the frame via at least one orifice. Each channel is able to deliver conditioned air to at least one region and typically each channel delivers the air to a different region. The at least one channel and at least one orifice is able to be connected to the at least one branch such as 202 sufficient to allow compressible or non-compressible fluid to flow. It is possible for different types of compressible or non-compressible fluid to be in different channels or be in the same channel at different sections where typically each channel is able to feature fluid separators that seal at least one section of at least one channel from at least one other section of the same channel.
Furthermore the non-compressible fluid is able to be fire retardant foam or other such fire retardant such that in the case of a fire in the vehicle or chair or other such the non-compressible fluid is able to exit the at least one channel and or at least one frame section of extinguish or limit the fire.
This is also true in terms of terms of compressible fluid in that an inert gas is able to be located in the at least one channel and or frame and exit the frame under certain conditions.
Furthermore the non-compressible fluid is able to be pressurised or other such to add strength and or different properties to the least one frame. Further still, the compressible fluid is able to be oxygen and as such oxygen is able to be circulated through the at least one channel and exit via at least one orifice in the frame and or via the orifice into the at least one branch such as 202. This ability to delivery oxygen in such a way is able to encapsulate the occupant in an oxygen enriched atmosphere which is able to for instance heighten driver response or for instance allow an elderly or low mobility occupant to forego the wearing of an oxygen mask. Other compressible fluids are able to be delivered in this manner include those that are able to serve a stimulant or relaxant affect to the occupant. The method is further able to be applied to other forms of drug delivery include the placement of particulates in the compressible fluid to be inhaled by the occupant.
With reference to
Therefore as the occupant places pressure on the coverings, so they will place pressure on the at least one plate and the at least one cross member. As previously described this pressure is able to make the cross member and or plate flex inline with the designed in and or material characteristics as well as the relative flexure capabilities and properties of the other backrest sprung components. In this case and additional to that previously discussed, as the at least one plate start to flex, the shaped channels such as 220A, 220B, 222A and 222B will generally either open further or close and thus they will move in their respective first directions. Typically the shaped channels 220A and 222A will close but the channels 222B and 220B will open depending on the overall pressure and their design and when pressure is released they will move in the second direction which means one inner channels open and the outer channels close. Therefore the relative stiffness or flexure of the at least one shaped channel will directly effect the movement of the at least one plate and all other backrest strung components.
Under further examination, as the pressure is applied to the coverings the at least two inner channels 220A and 222A will close and this at first opens the at least one corresponding outer shaped channel 220B and 222B. However, as the pressure increases and the inner channels close further, the outer channels will being to open further as the at least one collar 240 will begin to slidably rotate around the at least one frame axis moving in its respective first direction and when pressure is released the collar will move in the second direction. Therefore the sprung action is several fold, firstly the inner shaped channels, second outer shaped channels, thirdly the relationship between the collar and the outer shaped channels and finally the relationship between the collar and the at least one frame. All of these are able to be manipulated in terms of their flexural capabilities and properties depending on the desired output and with relation to the other backrest sprung components.
Further still the connection 224 between the rotary actuators is able to have flexural properties and characteristics as are the blocks 226A and 226B. Therefore as the inner shaped channels deform, generally closing and the at least one plate begins to flex and form a generally curved shape, so the axis of the blocks moves relative to the plate curvature and flexural properties and characteristics of themselves as well as the inner and outer channels and the other backrest sprung components.
Therefore, as the occupant places pressure on the coverings, pressure is applied to backrest sprung components and the components referenced above and namely the inner and outer channels, the blocks and the connection member 224 will move in their respective first directions and the cross member and plate will move and typically but not limited to form a curvature respective to the characteristics and properties of all the components referenced above. As the pressure is reduced from the occupant, the components will move in the second direction respective to the characteristics and properties of all the components referenced above.
Each component is able to features different properties and or characteristics not only in the first and second direction but also with regards to limits within each direction respective to pressure and movement completed. Therefore and purely for example if the overall travel of the combined components was X then at half X the properties and characteristics would change and for example the overall flexure of all components is able to become less (the components response stiffens) and or at half X the response may change with regards to pressure applied in that if more pressure is applied irrespective of in combination with overall amount travelled the response of the components may become stiffer, but at the same point travelled in the first direction the response for a lesser pressure may get less stiff and more flexure may be observed. Typically but not limited to this is also true for all circumstances in the second direction, however, the second and first direction capabilities and properties are able to be different.
Typically the various components of the system are able to be varied in terms of stiffness by simple means of adjustment. For anyone skilled in the art, the connection 224 may have a screw thread that is able to be tightened or slackened to alter the connections tension and thus alter the response of the overall backrest to applied pressure. In other cases, different blocks and or cross members and or plates and or bearings such as 238 can be used. It is also possible to incorporate pneumatic and or hydraulic adjustability into the backrest sprung components and with relation to all other components of the backrest where relevant. The most obvious location would be to replace the connection 224 with a pneumatic or hydraulic cylinder. Typically either cylinder (pneumatic or hydraulic) is able to be adjusted in terms of response.
It is also a consideration that typically the at least one fluid or gel layer 216 has holes through which non-compressible and or compressible fluid is able to pass. Typically but not limited to at least one foam layer above and below the at least one layer 216 will typically feature corresponding holes for the same purpose. However and typically but not limited to the at least one foam layer nearest the outer covering 242 will not have any holes such that the non-compressible and or compressible fluid will diffuse over a wider area and generally evenly throughout the region of interest.
The ability for the components as referenced to react differently when exposed to different pressures and at different travelled points in the first or second direction allows the characteristics and properties of each to be varied such that during a high pressure, high travel scenario which is able to occur very quickly (over a short space of time) means that the backrest is able to feature designed in characteristics and properties whereby in a crash (were the seat and or backrest be fitted to or in a vehicle) the occupant is able to be generally centred and optimally supported irrespective of the crash vector (direction) and impact force.
Purely for example if the occupant is located to the first side of the backrest and that backrest is fitted within a vehicle, in the result of that vehicle being involved in a crash then the components on first side of the backrest would be exposed to a higher pressure than those on the second side of the backrest. If the characteristics and properties of the first and second side allowed for slower travel in the first direction with a higher pressure but faster travel with a lower pressure, over the course of the first directions movement the occupant would be both better support and moved towards the centre and or centred respective to the backrest. Furthermore if at least one component had properties to return faster on the side which absorbed the higher pressure, then the first side would return (move in the second direction) more quickly than the second side and as such the occupant would be more supported and would be further moved towards the centre and or centred respective to the backrest.
Of course anyone skilled in the art will relies that many combination of properties and characteristics are able to be used respective to each component and respective to how all the components react with each other and in relation to the occupant and the desired affect on the occupant, we have not covered all those here, but the example clearly indicates the ability of this backrest system.
The covering 304 is also able to feature an outer fabric covering such as a material suitable for the usage of the seat. Typically but not limited to this fabric material is able to surround the seat section and be permanently or removably attached or integrated to the frame. The covering 304 is located on the at least one plate 306 whereby at least one layer of the covering is able to be permanently or removably attached or integrated with the at least one plate. The at least one plate 306 is able to feature numerous sections with different properties and characteristics and or multiple plates are able to be used in the seat.
Underneath the at least one plate 306 is at least one spring plate 308 whereby the spring plate is removably or permanently attached and or integrated to the at least one seat frame or seat frame section. Underneath the at least one spring plate 308 is at least one is an optional at least one transfer board 302. Typically the optional transfer board is only used when certain types of mechanism are placed into the mechanism space 300. The transfer board allows forces and movement of a mechanism to be transferred to the seat and/or backrest and/or the integrated seat 1. Typically but not limited to the transfer board is only used where CAM or CAM based mechanisms are used and the transfer board (although not shown) is able to be permanently or removably attached or integrated into the at least one seat frame.
The mechanism space 300 is as above typically but not limited to a space where CAM based mechanisms are able to be located in order that they are able to move the integrated seat or the seat or the seat and a backrest. It will be obvious to someone skilled in the art that other types of mechanism are able to be located into the space and thus the space is not limited to the use of CAM mechanisms, any suitable mechanism is able to be situated in the space.
It will also be appreciated by someone skilled in the art that if no mechanism is to be situated in the space then the overall depth of the seat is able to be reduced as the space is no longer required. Typically but not limited to the at least one covings 304, at least one plate 306 and at least one spring plate 308 will be situated more within the overall height of the frame and generally towards the front frame bar 312. As will be appreciated this will significantly reduce the overall depth of the seat.
The at least one space is able to also feature the optional at least one bottom transfer board 310. Typically the bottom transfer board has all the same features and functions as the top transfer board and is used for all the same reasons with regards to CAM mechanisms. The CAM or any other such mechanism is able to be locked to either the top or the bottom depending on lift requirements and or if the integrated seat 1 is being lifted or just the seat is being lifted. In its most basic form a mechanism is able to use the at least one bottom plate 310 as a base on which to be secured or as a transfer board.
In the first instance, the bottom is able to have any lift mechanism permanently or removably and or movably attached or integrated and typically but not limited to taking the CAM mechanism as the at least one CAM rotates in the first direction the seat and or integrated seat lifts whilst the CAM mechanism stays secured to the bottom plate. However, it is possible for the CAM mechanism to be permanently or removably and or moveably attached to or integrated with the at least one top plate 302. In this case as the CAM mechanism rotates typically in the second direction the seat and or integrated seat lifts. This ability of either the top of bottom plate to be used as a base and or transfer board enables the seat to move independently of the backrest or with the backrest dependent on if the seat is decoupled from or coupled to the backrest.
Typically both the at least one top and bottom plates 302 and 310 are able to feature at least one profile and or at least one guide track which typically but not limited to contains a open or closed channel which is able to be profiled if required.
The ribs are also able to be used to house other items such as the anchor 328. The anchor 328 is permanently or removably attached to or integrated with the at least one frame and or at least one rib. The anchor is also permanently or moveably attached to or integrated to the at least one spring plate 302. Typically this association forms the first suspension or sprung system for the seat. The at least one plate 306 typically but not limited to forms the second suspension or sprung system of the seat. The plate has a sprung section such as a shaped element with at least one curve and or radius and or at least one tine like leaf type spring arrangement. This general curve and or tighter radius and or tine like leaf spring is permanently or removably attached or integrated to a collar 324. The collar has all the same functions and features as the collar 240. The collar is positioned around the at least one frame 322 and is permanently or removably or moveably attached or integrated to the frame. Typically the collar is movably attached to the frame.
The figure also shows the cover section 304 in more details, the covering 304 contains at least one outer fabric cover 318, the at least one layer of high density foam 314 and the at least one gel or fluid section 316 and the at least one foam layer 320. Any combination of foam, high density foam and or gel or fluid section is able to be utilised and as such is akin to the backrest coverings.
The at least one plate 306 and collar 324 as well as the at least one spring plate 302 and anchor 328 are all able to be manufactured from at least one material and are able to be a composite of at least two materials. The materials are able to but are not limited to having flexural properties and capabilities with the overall flexural properties and capabilities relative to the materials and or the designed in characteristics and or the relative association and interaction to the respective flexural properties and capabilities of the other referenced at least one component.
Taking the first and second suspension systems which form the seat sprung components, it is able to be shown that as an occupant increases pressure on the covering 304 the covers will absorb some pressure and then pass on pressure to the at least one plate 306. As pressure increases the at least one plate 306 will begin to flex typically the curved and or radius or tine section will start to move in the first direction and generally increase its curve or curvature. As the pressure increases the plate 306 will interact more heavily with the spring plate 302 and as such the spring plate 302 will move in the first direction and will begin to generally form a curve. As the pressure further increases, the relative section of the at least one plate will begin to move further in the first direction and as such the collar will begin to move in the first direction and rotate about the axis of the at least one frame. The at least one plate 302 will also move further in the first direction and as such the relative section will increase in its general curvature and increase the pressure the anchor transfer to the at least one frame.
As the pressure is released the first and second suspension systems which form the overall seat sprung system will move in the second direction. The characteristics of the first and second direction are able to be different not only with relation to each individual component but also with relation to each of the other components. As such the seat sprung system is able to be designed such that the system is tailored to the desired usage and safety.
Before examples are introduced, the figure also shows a further component of the seat sprung system that of the spring link 326. The material of the spring link is able to be but not limited to having flexural properties and capabilities with the overall flexural properties and capabilities relative to the materials and or the designed in characteristics.
The spring link is able to be permanently or removably attached to or integrated with both the at least one anchor 328 and the at least one plate 302. Therefore as the plate spring plate 302 moves in the first direction so will the link 326 whereby the link 326 passes the movement to the anchor 328. The flexural capability and properties of the link are able to be such that the link does not initially transfer movement or force of the plate to the at least one anchor. Furthermore the at least one plate is able to be such that it features at least two and typically but not limited to several lugs and each lug is able to be connected to both its own and or separate individual anchor and its own and or separate individual link.
Properties and characteristics of each of the lugs and each of the individual anchors and links are able to be different to at least one or the same as at least one other of the respective lugs and or anchors and or links. The links 326 are part of the second suspension system and as such part of the overall seat sprung components.
Typically the seat sprung components are able to be arranged such that the properties and characteristics of them allow for the occupant to be supported in a tailored fashion and or repositioned in the seat. With respect to tailoring the properties and characteristics are able to be such that and purely for example, a low mobility user whom tends to locate more toward one side of the seat rather than the other in that they apply more pressure to one side of the seat more than the other is able to have a more central, supportive and or corrective posture imposed on them by varying at least one of the properties and characteristics of the at least one seat sprung components. Typically the varying of the at least one seat sprung components will see stiffer components on the side to which they are more towards and less stiff components on the opposite side. Typically the net result is that the occupant will be centred in the seat with move even pressure distribution and a more support and or correct posture.
In terms of a repositioning, this could occur if the seat was to be located in a vehicle and that vehicle was involved in an accident and typically a collision. Irrespective of the impact vector and irrespective of where the occupant is located in the seat unless already in the optimum central position, the properties and characteristics of the at seat sprung components are able to be configured such that they have different flexure rates depending on the amount they have travelled in the first and or second direction as well as the amount of pressure as well as the speed at which the increase in pressure occurs.
Therefore and purely for example, if the occupant is more towards one side than the other and a crash or impact occurs on the vehicle, then the pressure will increase more in one region of the seat than the other. In this case at least one of the seat sprung components typically on the opposite side to where the occupant is more biased towards will flex more quickly in the first direction and with less pressure than the sprung components typically on the same side to where the occupant is biased and thus the occupant will be repositioned generally in the centre of the seat. In the second direction both sides of the seat sprung components are able to flex equally as quickly as each other and thus keep the occupant central in the seat.
Of course these are examples, but anyone skilled in the art will understand that the flexural properties at least one of the seat sprung components is able to be altered to affect the occupant with a view of allowing them a more supported and safer seat.
Other examples are such that towards the front of the seat sprung components is able to be more flexural than the rear and or any region of the seat is able to be more or less flexural than another region.
Further still if the collar 324 is movably with respect to the frame, then a bearing and or lubrication is able to be present between the collar and the frame.
The figure illustrates that at least one plate 306 is attached as has been referenced previously. Typically but not limited to the plate is able to be in several individual sections or one main section where each section is able to feature different flexural properties and characteristics. The at least one plate is shown here cut away such that the aspects underneath the plate are able to be better shown.
As illustrated, at least one dual locking means 360 are able to be located within the boundaries of the frame. The dual locking means have been described previously. In this case the dual locking means would be engaged with the backrest (not shown) whereby the backrest frame would feature extensions which would engage with the arm of the dual locking means. Therefore as the dual locking means advanced in the first direction, the locking arms 364 (shown in
As the dual locking means retracts in the second direction, the locking arm would withdraw from the seat frame but be retained in the backrest frame. When the locking arm retreats and the rear locking means 366 (from
Typically the backrest frame would pass through the rear frame 376 whereby the backrest frame can be further locked in position by the at least one locking unit and typically two locking units. As the backrest engages with the seat, the locking units end section 336 advances and moves into the backrest frame both applying pressure to the backrest frame and locking into position such that it moves with the seat. Typically if the locking means retracts the end section retracts and unlocks and depressures the backrest such that the seat is able to move independently of the backrest.
The seat frame is able to also feature at least one support structure 120, whereby the at least one and typically two members are located in the seat frame either at the front and or the rear. The illustration shows the two support structure at the rear of the seat frame with the linear actuator sections within the seat 380 and 322 respectively. Typically the at least one support structure is permanently or removably attached and or integrated into the seat frame. The support structure typically have two sections as has been described, the linear actuator section and the rotary actuator section. In this case the rotary actuator sections are coaxially located and they are able to be permanently or removably attached or integrated to a frame or a vehicle or a mount or other support structure located in said frame and or vehicle and typically this is achieved via the at least one support structure rotary actuator exit shaft.
The backrest as stated is able to connect to the seat as described above and the backrest as has also described has its own rotary capability. Therefore the seat is able to attach to a frame or vehicle or mount or other support structure such that the rotation of the at least one rotary member of the seat (as shown here) will result in the backrest and the seat rotating about the axis of the at least one support structure's 120 exit shaft axis. It is also apparent that the extension of the linear actuators will move not only the seat but also the backrest (if it is connected to the seat) linearly. The linear and rotary actuators of the at least one support structure 120 are able to operate simultaneously or independently at the same or different relational speeds. It is also apparent that the seat support structure is able to move the seat linearly and rotationally with or without the backrest being connected to the seat.
The rear part of the frame 376 can feature at least one locking device 350. The locking devices are typically encapsulated in the frame. Two locking devices are shown such that when the backrest is positioned through the seat frame as described above and is being locked into place respective to the locking members 360 the two locking devices can also operate and as such the locking means 366 (from
In this case the manifold supplies at least one region of the seat. Typically the seat has at least four regions but in this case the seat is shown with two regions. The left region 394 and the right region 396 are able to receive the supplied fluid whereby and akin to the backrest fans 392 and 388 respective to each region circulate the fluid around the region. The at least one plate is able to feature at least one hole 386 and typically features multiple holes per region. Therefore the fluid is able to exit the holes and the covering 304 to occupant. Typically but not limited to the at least one cushioning layer immediately underneath the cover 318 and typically but not limited to 314 will not feature holes and thus defusing the fluid over the region, however the cushion layers beneath 314 such as 316 and 320 typically but not limited to do feature holes aligned with the holes in the plate to allow fluid to more easily reach the outer cover 318.
The seat is also able to feature at least one heater elements 390, the heater element is able to be retained to the plate 310 or be encapsulated between or within the covering layers of 304 such as 314, 316 and 320 from
The seat and the backrest are both able to feature at least one gel or fluid section as has been referenced, in the case of the backrest this is 216 and in the 316. Each of the gel or fluid sections is able to feature at least one section and typically has multiple sections. Each of the at least one sections has the ability to feature at least one valve or valve element.
The at least one valve or valve element has the ability to open respective to the pressure of the gel or fluid within that section or at least one adjoining section, thus when the fluid or gel in at least one section reaches a certain pressure the at least one valve or valve element may open or remains closed therefore fluid or gel may move to at least one other section or be retained in at least one section. Furthermore when a certain pressure has been achieved and in the case of a valve or valve element being open, then the valve or valve element will close and thus retain some or non of the gel or fluid. Each at least one valve or valve element is able to open and or remain closed respective to different conditions which may include temperature and pressures as well as the speed at which the pressure increases or decreases.
Purely as an example and not to be limited to in any way, many sections can be present within the at least one section 216 and or 316. Each of the section is able to feature at least three valves whereby the fluid or gel is able to enter and exit the different section to other sections. Therefore if the at least one first section against the side of the seat and or backrest is taken, then at least one second section that borders the first is able to move fluid or gel into the at least one first section when pressure increases upon it.
Typically this presents itself when and for example a vehicle starts to corner and the occupant's pressure is increased towards the side of the seat and or backrest. As the occupant increases pressure resultant from the corning forces the at least one second section at least one valve is able to open and transfer gel of fluid into the at least one first section. This increases fluid or gel in the at least one first section and as such increases the support able to be provided by the first section to the occupant at the side of the seat and or backrest and thus is able to assist in keeping the occupant generally central in the seat and or backrest.
This is also true in terms of a collision whereby forces are exerted on the occupant and as such the pressure applied to the at least one section and typically at least two sections changes respective to the direction of the impact and magnitude of the load. In this case the at least two sections and at least one valve or valve element therein are able to be arranged such that the occupant is supported and able to be generally centred in the at least one seat or backrest.
Typically but not limited to the at least two sections and at least one valve or valve element therein are able to arranged such that the posture of the occupant is also generally adjusted to both provide optimum support and maximum safety protection.
For a further example for a typically but not limited to elderly or reduced mobility occupant is also able to benefit from the fluid and or gel usage. Using the seat and or backrest in a conventional domestic type chair, as the occupant increases pressure resultant from medical condition, the at least one second section and at least one valve is able to open and transfer gel of fluid into the at least one first section. This increase in fluid or gel in the at least one first section increases the support able to be provided by the first section to the occupant and thus assists in keeping them central to the seat and or backrest and increasing pressure relief where it is most required.
This is also true in terms of a posture whereby pressure exerted by the occupant resultant from how they sit and or their body's form and or any condition such as reduced mobility is able to be used as such that the pressure applied to the at least one section and typically at least two sections and at least one valve or valve element therein are able to be arranged such that the occupant is supported with a generally better posture and or generally centred in the at least one seat or backrest. The at least one section and or at least one valve or valve element therein is able to be tailor made to any occupant or usage requirement. It is also preferable that the at least one section and or at least valve or valve element therein is able to be designed and occupant affect and or affects integrated with the seat and or backrest sprung components in whole or in part.
Furthermore, the seat and/or backrest sprung components properties and characteristics and especially with regards to flexure, both as a whole or in part, are able to be different and/or at least one component therein is able to be different to at least one other component therein. However, the backrest sprung components and the seat sprung components as well as the gel and or fluid at least one section properties and characteristics and especially with regards to flexure and or fluid or gel movement relational to pressure are able to be harmonised. Typically the harmonisation is to optimise the support for the occupant and increase the safety protection offered to them.
Purely for example, typically the seat and backrest sprung components and or the at least one fluid or gel section with its at least one valve or valve element are able to be arranged such that the properties and characteristics of them allow for the occupant to be supported in a tailored fashion and or repositioned in the seat and or backrest and therefore the integrated seat.
With respect to tailoring the properties and characteristics are able to be such that and purely for example, a low mobility user whom tends to locate more toward one side of the seat and or backrest in that they apply more pressure to one side of the seat and or backrest than to the other is able to have a more central, supportive and or corrective posture imposed on them by varying at least one of the properties and characteristics of the at least one seat sprung and or backrest components and or the at least one fluid or gel section with its at least one valve or valve element.
Typically the varying of the at least one seat sprung and or backrest components and or the at least one fluid or gel section with its at least one valve or valve element will see stiffer components and or higher pressure bearing values on the side to which they are more towards and less stiff components and or lower pressure bearing values on the opposite side.
Typically the net result is that the occupant will be centred in the seat and or backrest with move even pressure distribution and a more support and or corrected posture.
In terms of a repositioning, this could occur if the seat and or backrest were to be located in a vehicle and that vehicle was involved in an accident and typically a collision. Irrespective of the impact vector and magnitude of the collision and irrespective of where the occupant is located in the seat and or backrest, the properties and characteristics of the at least one seat sprung and or backrest components and or the at least one fluid or gel section with its at least one valve or valve element are able to be configured such that they have different flexure rates and or valve opening and or closing pressures depending on the amount they have travelled in the first and or second direction and or the volume of fluid or gel in them as well as the amount of pressure and or speed at which the increase in pressure occurs.
Therefore and purely for example, if the occupant is already in the optimum position, they will be retrained in the optimum position, however, if the occupant is more towards one side than the other and a collision or impact occurs on the vehicle, then the pressure will increase more in one region of the seat and or backrest than the other.
In this case at least one of the seat sprung and or backrest components typically on the opposite side to where the occupant is biased will flex more quickly in the first direction and with less pressure than the sprung components typically on the same side to where the occupant is biased and or the at least one fluid or gel section on the opposite side to where the occupant is biased will not receive any fluid or gel from the at least one other fluid or gel section from the side to which the occupant is biased, however, the at least one fluid or gel section on the biased side may open at least one valve to allow some fluid or gel to move to at least one other fluid or gel section on the same side and thus the occupant will be repositioned generally in the centre of the seat and or backrest. In the second direction both sides of the seat and or backrest sprung components are able to flex equally as quickly as each other and or at least one fluid or gel section on both sides may open at least one valve and evenly distribute the fluid and or gel and thus keep the occupant central in the seat.
Of course these are examples, but anyone skilled in the art will understand that the flexural properties at least one of the seat and/or backrest sprung components and/or the at least one fluid or gel section are able to be altered to affect the occupant with a view of allowing them a more supported and safer seat and or backrest. Other examples are such that towards the front of the seat and or lower part of the backrest sprung components and or at least one fluid or gel section with at least one valve and or valve element are able to be more flexural and or open and close at different pressures than the rear and or top section and or any region of the seat and or backrest and or at least one valve of valve element of the at least one fluid or gel section is able to be more or less flexural and or open and close at a different pressure than another region and or any other valve and or valve element in any other fluid or gel section.
It will be further appreciated that the at least one frame of the seat and or the backrest is able to have flexural properties and characteristics which are able to be harmonised with the seat and or backrest sprung components and or the at least one gel or fluid section and the at least one value thereof. This means that the above examples in terms of flexure would incorporate the flex provided by the backrest and seat frame with the same resultants, that of, occupant optimised safety, support and comfort.
The present invention uses prior art from other Corcost patents such as and including the Gearbox patent. It will also be obvious to those skilled in the art that the formation of the seat described herein is not limited to just the automotive sector, moreover the seat formulation can be applied to any seat for any sector such as a medical chair, dental, salon chair or any other suitable chair application.
Claims
1. A support section for a seat comprising a load responsive framework wholly or partially enclosed in amorphous upholstery, the frame work comprising multiple independently operable load responsive sub systems which collectively permit the support section to respond and react to local areas of loading whereby to provide superior support and comfort to the seat occupant.
2. A seat comprising one or more support sections as claimed in claim 1 embodied as the whole or a part of; a seat back rest and/or a seat base.
3. A seat as claimed in claim 2 wherein the support section is embodied as a lumbar support of a seat backrest.
4. A seat as claimed in claim 1 comprising an integrated backrest and seat base, the backrest and seat base both including one or more support sections.
5. A support section or seat according to claim 1 wherein the upholstery comprises one or more materials selected from: an energy absorbent material, a contained fluid and a foam.
6. A support section or seat as claimed in claim 5 wherein a plurality of different materials are laminated to provide the upholstery.
7. A support section or seat as claimed in claim 6 wherein the laminate comprises; an outer cover layer enclosing at least one foam layer, and a fluid/gel filled layer.
8. A support section or seat as claimed in claim 5 wherein the fluid/gel filled layer comprises two or more sections in fluid communication controlled by one or more valves permitting the redistribution of the fluid/gel between the sections when any one or more sections is under load.
9. A support section or seat as claimed in claim 8 wherein the valve or valves are configured to have a different opening pressure requirement for each of the directions of travel of fluid between any two sections.
10. A support section or seat as claimed in claim 5 comprising a foam which is a high density foam.
11. A support section or seat as claimed in claim 5 comprising a foam which is fire retardant.
12. A support section or seat as claimed in claim 5 wherein in one or more of the enclosed layers is pressurised.
13. A support section or seat as claimed in claim 5 wherein the contained fluid is at least partly gaseous.
14. A support section or seat as claimed in claim 13 wherein the gas comprises oxygen.
15. A support section or seat as claimed in claim 7 wherein the cover layer is configured to have a low friction surface on the surface which interfaces with the enclosed layers.
16. A support section or seat as claimed in claim 1 wherein one or more of the sub systems comprises a position adjustment mechanism comprising a drive arranged to drive a lead screw in rotation about the lead screw's central axis;
- a toothed drive meshing with the lead screw, rotation of the lead screw causing linear motion of the toothed drive;
- the toothed drive independently meshed with a first gear wheel, linear motion of the toothed drive causing rotation of the first gear wheel;
- a second gear wheel meshed with the first gear wheel, rotation of the first gear wheel in a first direction causing rotation of the second gear wheel in an opposite direction;
- the second gear wheel meshing with a toothed rack, the toothed rack arranged in parallel alignment with the toothed drive and rotatably mounted to permit rotational movement about the linear axis of the toothed rack, rotation of the second gear wheel resulting in linear travel of the first and second gear wheels and toothed drive along the length of the toothed rack.
17. A support section or seat as claimed in claim 16 wherein the position adjustment mechanism further includes a third gear wheel which meshes with the toothed rack and whilst free to rotate is fixed in position relative to the second gear wheel.
18. A support section or seat as claimed in claim 17 wherein the three gear wheels of the position adjustment mechanism are contained in a casing, the casing adapted not to restrict the linear motion of the gear wheel system relative to the toothed rack.
19. A support section or seat as claimed in claim 16 wherein rotation of the toothed rack in the position adjustment mechanism is countered by a biasing mechanism.
20. A support section or seat as claimed in claim 16 wherein the drive for the position adjustment mechanism includes a drive shaft which is an output shaft of a rotary actuator.
21-67. (canceled)
Type: Application
Filed: Aug 11, 2010
Publication Date: Jan 24, 2013
Inventor: Steven Corcoran (Cawood)
Application Number: 13/638,749
International Classification: A47C 7/02 (20060101); A47C 27/08 (20060101); A47C 7/24 (20060101); A47C 7/40 (20060101); A47C 7/18 (20060101);
