ARTICULATING HEAD RESTRAINT MECHANISM

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a PCT application claiming priority to United States Provisional Patent Application Serial Number 60/641,033, filed January 3, 2005, which is incorporated herein by this reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to the field of head rests or head restraints. More particularly, the present invention relates to a mechanism for locking and articulating a head restraint.

BACKGROUND OF THE INVENTION

[0003] Head restraints or head rests for automotive seats are well known. It is known to provide a head restraint that extends upward from a seat back of a vehicle seat. It is also known to provide a height adjustable head restraint. [0004] Seats which are capable of being collapsed into a stowed or a storage position allow for increased driver visibility, as well as allowing for more flexibility in the use of the interior space of the vehicle, such as by providing additional cargo space or improving access to other areas of the vehicle. However, head restraints used with collapsible vehicle seats often cause interference with other portions of the vehicle. For example, there may be insufficient clearance to fold or collapse a seat forward because of the increased height of the seat back due to the head restraint. In particular, during the collapse of a second or third row seat, the head restraint often makes contact with the seatback of the seat positioned in front of it.

[0005] It would be advantageous to provide a head restraint system that articulates to a generally stowed or folded position and reduces the length of the seatback member to allow the seat to be collapsed without interference between the head restraint and portions of the vehicle. Particularly, there is a need for such a head restraint system which is able to be easily actuated by the appropriate user depending on the location of the seat. Further, there is a need for a head restraint system which includes multiple actuation mechanisms to fold the head restraint so as to allow a user located at various positions to fold the head restraint.

For such a head restraint system, a locking mechanism is needed which is capable of communicating with the multiple actuation mechanisms within the limitations imposed by the structure of the head restraint.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a head restraint system for use in a vehicle seat assembly. The seat assembly includes a lower seat and a seat back having an upper portion with at least one aperture for receiving a support member. The seat back is pivotally coupled to the lower seat and configured to move between a use position and a storage or stowed position. In the use position, the seatback is substantially upright. In the storage position or stowed position, the seatback folds forward and the seat back is substantially parallel with the lower seat.

[0007] The head restraint assembly includes a support member and a head restraint member rotationally coupled to the support member. The support member includes upright members and a cross member which is positioned substantially perpendicular thereto. The cross member is disposed within and affixed to a barrel mechanism which includes a grooved portion. The head restraint is mounted to be rotatable about the barrel mechanism. In one embodiment, the grooved portion includes locking grooves positioned laterally on the barrel mechanism. In another exemplary embodiment, release grooves are positioned circumferentially on the barrel mechanism substantially perpendicular to the locking grooves and forming a continuous groove therewith.

[0008] A shuttle is provided in communication with the barrel mechanism to form a locking mechanism to selectively prevent the head restraint from rotating. The shuttle has teeth which are adapted to engage the grooved portion, wherein when the teeth are engaging the locking groove, the head restraint is not free to rotate and when the teeth are disengaged from the locking groove, the head restraint is free to rotate. Furthermore, the teeth of the shuttle are designed in size and detail such that when the shuttle is lifted a predetermined distance such as by lifting the bottom of the head restraint, the teeth are removed from the matching groove and the head restraint is free to rotate. In an exemplary embodiment, additional release mechanisms are provided in communication with the shuttle to selectively move the teeth from the locking groove to the release groove.

[0009] In one embodiment, a manually operated actuator in the form of a button is provided which, when depressed, actuates the shuttle to release the headrest. In one

exemplary embodiment, the actuator is located on the side of the head restraint. In another embodiment, the actuator is located on a back of the head restraint. In yet another embodiment, a actuator is located on a bottom of the head restraint. In another exemplary embodiment, a release mechanism is provided whereby the shuttle is actuated to the unlocked position when the seatback is folded down.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a partial, side-plan view of a head restraint in accordance with the principles of the present invention;

[0011] FIG. 2 A is a perspective view of one embodiment of the head restraint assembly in an upright position;

[0012] FIG. 2B is a perspective view of the head restraint assembly of FIG. 2A in the stowed position;

[0013] FIG. 3 is an exploded view of a head restraint of the present invention;

[0014] FIG. 4 is a partial perspective illustration of the head restraint assembly of the present invention in the upright position;

[0015] FIG. 5 is a perspective view of the shuttle;

[0016] FIG. 6 A is a rear perspective view of the head restraint assembly and support member with the head restraint cover in place;

[0017] FIG. 6B is a partial perspective illustration of the head restraint assembly of FIG. 6A, with the head restraint cover removed;

[0018] FIG. 7 is a detailed, partial plan view of the barrel mechanism of FIG. 6B;

[0019] FIG. 8 A depicts a front perspective view of an embodiment of the support member having curvilinear support posts and an actuation mechanism on the bottom of the head restraint; [0020] FIG. 8B is a partial, front plan view of the top of the curvilinear support posts of

FIG. SA;

[0021] FIG. 8C is a partial, side view of the top of the curvilinear support posts of FIG.

8A;

[0022] FIG. 9 is a partial perspective view of an embodiment of the head restraint having an actuation mechanism on the back of the head restraint;

[0023] FIG. 1OA is a front view of one embodiment of a head restraint mechanism of the present invention;

[0024] FIG. 1 OB is a front view of the head restraint mechanism of FIG. 1 OA with the head restraint cover removed;

[0025] FIG. 11 is a partial front perspective view of one embodiment of a shuttle and barrel mechanism positioned in a head restraint of the present invention, wherein the teeth are engaging the groove to prevent rotation of the head restraint; and

[0026] FIG. 12 is a partial front perspective view of the head restraint of FIG. 11, wherein the teeth are disengaged from the groove by lifting the head restraint to allow rotation of the head restraint.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] A seat assembly 10 is a folding seat assembly configured to move between a use (design) or first position and a storage or second position. The seat assembly 10 is preferably configured for use in a second or third row of seats in a vehicle, such as a sport utility vehicle, minivan, full-size van, pick-up truck, hatchback, station wagon, etc. The seat assembly 10 may also be used as a first row seat of a vehicle, and may be particularly applicable as a front passenger seat. In another exemplary embodiment, the seat assembly 10 may be used in other various vehicle applications, such as boats, airplanes, or trains. [0028] In an exemplary embodiment shown in FIGURE 1, the seat assembly 10 includes a seat back 14 having an upper portion 22, a lower portion (not shown), a front portion 20, and a back portion IS; and a head restraint system 30 coupled to the upper portion 22 of the seat back 14. As shown in FIGURES 2A and 2B, the head restraint system 30 of the seat assembly 10 includes a support member 28 for pivotally coupling the head restraint assembly 16 to the upper portion 22 of the seat back 14.

[0029] The head restraint system 30 includes the support member 28 coupled to and extending through the upper portion 22 of the seat back 14. The head restraint system 30 is configured to rotate forward from an upright or head support position (FIGURE 2A) to a stowed or non-occupied position (FIGURE 2B). In the head support position, the support member 28 extends upward from the seat back 14 for supporting the head restraint system 30 in a generally upright position relative to the seat back 14. In the stowed position, a front portion 27 of the head restraint system 30 is near the front portion 20 of the seat back 14. [0030] When the seat assembly 10 is moved into the storage position, the head restraint system 30 is configured to fold (e.g., retract, collapse, move, etc.) forward (i.e., inward) relative to the front portion 20 of the seat back 14 to provide increased clearance between

the collapsing seat assembly 10 and other articles within the vehicle (e.g., seats positioned in front of the collapsible seat, instrument panels, overhead components, consoles, etc.). The head restraint system 30 may be in an upright position (FIGURE 2A) or a folded position (FIGURE 2B) and may be in a locked or a free (i.e., unlocked) state. [0031] Referring to FIGURES 2A and 2B, the support member 28 is mounted to and extends outwardly from the upper portion 22 of the seat back 14. In one embodiment, a mounting bracket 25 is provided to retain the support member 28 on the seatback 14. According to a preferred embodiment, the support member 28 comprises a pair of support posts 36, 38 having upper ends 40, 44 and lower ends 42, 46, respectively, and a cross member 26. Preferably, the support posts 36, 38 are solid members having generally circular cross sections. According to an exemplary embodiment, support posts 36, 38 are tubular members having generally circular cross sections. As can be appreciated, support posts 36, 38 may have any of a variety of cross sections such as, but not limited to, rectangular, octagonal, elliptical, triangular, trapezoidal, etc. It should be noted that while a pair of support posts 36, 38 are illustrated in the figures, the present invention is equally applicable to an embodiment having one support post.

[0032] As previously stated, the support member 28 further includes the cross member 26 which is joined to the support posts 36, 38. In an exemplary embodiment shown in FIGURES 6A and 6B, the support posts 36, 38 may be joined by the cross member 26 positioned near the upper ends 40, 44 of support posts 36, 38 and substantially perpendicular to the support posts 36, 38. In one embodiment, the cross member 26 is integrally formed with the support posts 36, 38 to form a general U-shape. [0033] Referring to FIGURES 2A and 2B, the upper ends 40, 44 of the support posts 36, 38 are configured to support the cross member 26 which supports the head restraint system 30. The upper ends 40, 44 of the support posts 36, 38 and the cross member 26 are mounted into the head restraint system 30 using a conventional support post mounting mechanism as is well known in the art, with a slight play in the mounting whereby the head restraint system 30 can be lifted slightly. [0034] In one embodiment, the support posts 36, 38 are generally linear. According to another embodiment, the support posts 36, 38 are generally curvilinear members. In one embodiment, the curvilinear support posts 36b, 38b are substantially J-shaped as shown in FIGURES 8 A, 8B, and 8C. The bottoms, or curved portions of the J-shape correspond to the upper ends 40, 44 and the tops, or linear portions of the J-shape correspond to the lower

ends 42, 46. Curvilinear support posts 36b, 38b are joined via the cross member 26b. The head restraint system 30 is pivotally coupled to the cross member 26b in a manner which allows the inner portion of the J-shape to face forward, i.e. toward the direction in which the seat back folds. [0035] As best shown in FIGURE 3, the cross member 26 is disposed within and fixed to a barrel mechanism 50 which has a substantially circular outer circumference. The head restraint system 30 further comprises a housing 31 in which cross member 26 is disposed to allow the head restraint system 30 to rotate relative to the support member 28. In one embodiment, the housing 31 has a first portion 32 and a second portion 34. The head restraint system 30 is biased to the folded state by a biasing mechanism, such as spring 56 (FIGURE 4) or a pair of coiled springs 56a and 56b (FIGURE SB), located on the barrel member 50 and biased against the housing 31. In one embodiment, as shown in FIGURE 7, the locking grooves 59 are located at the top of the barrel mechanism 50 and positioned along the length of the barrel mechanism 50 substantially parallel with the lateral axis 29 of the cross member 26 and overlapping the release grooves 58 at an upper portion of the release grooves 58.

[0036] The barrel mechanism 50 includes a groove portion 51. A shuttle 60 is provided for engagement of the barrel mechanism 50 to selectively lock or unlock the head restraint system 30 via teeth 61 adapted to slot into the grooved portion 51. At least one locking groove 59 is provided in the grooved portion 51 for engagement of the teeth 61 to retain the ^' head restraint in a locked position. In one exemplary embodiment, the locking grooves 59 are positioned laterally on the barrel mechanism 50. Thus, in the locked state the teeth 61 engage the locking groove 59 to retain the head restraint assembly 16 in a locked position, as shown in FIGURE 11. ha one embodiment, the teeth 61 are moved to the release grooves 58, thus allowing the head restraint 30 to rotate forward. In another embodiment, the teeth 61 are disengaged from the locking grooves 59 by being lifted out of the locking grooves 59, to place the head restraint assembly 16 in a free position as shown in FIGURE 12. As seen in FIGURE 11, the teeth 61 initially are positioned in the locking groove 59 and when the head restraint is slightly lifted, the teeth 61 are removed from the locking groove 59 as shown in FIGURE 12. In an exemplary embodiment shown in FIG. 4, the teeth 61 may be lifted from the locking groove 59 or shifted to the release grooves 58 in order to allow the head restraint 30 to freely rotate.

[0037] In another embodiment, at least one release groove 58 is provided about the circumference of the barrel mechanism 50. In a further embodiment, the release grooves 58 are positioned perpendicular to the locking grooves 59 and form grooves continuous therewith as shown in FIGURE 4. In the locked state, the teeth 61 are positioned in the locking grooves 59. In the unlocked or free state, the teeth 61 are removed from the locking grooves 59 or are repositioned to the release grooves 58. In addition, in an exemplary embodiment, at least one additional mechanism is provided to release the head restraint system 30 from the locked state. In one embodiment, a release mechanism 65 is provided whereby the user may actuate the shuttle 60 to move the teeth 61 from the locking grooves 59 to the release grooves 58. The head restraint system 30 pivots about the cross member's 26 lateral axis 29 (FIGLTRE 4). In one embodiment, the shuttle 60 is biased to remain in the locked state by a spring 69a.

[0038] In one embodiment best shown in FIGURE 3, the head restraint housing 31 comprises a first portion 32 and a second portion 34. When the first portion 32 and the second portion 34 of the housing 31 are placed together, the curved portions 33, 35 form a hollow tubular space 74 within the housing 31 for rotatably engaging the barrel mechanism 50. The hollow tubular space 74 is sized such that the barrel mechanism 50 is loosely disposed therein to allow the head restraint system 30 to be moved slightly with respect to the barrel mechanism 50. The first portion 32 and the second portion 34 are affixed together by screws 72, or in an alternative embodiment, by any means known in the art. [0039] In one exemplary embodiment as shown in FIGURE 1OB, the shuttle 60 is affixed to the head restraint housing 31. The shuttle 60 is held vertically in position within the head restraint assembly 16 by the head restraint housing 31. In a preferred embodiment, the teeth 61 engage the locking grooves 59 in such a manner that slight relative movement apart is sufficient to disengage the teeth 61 from the locking grooves 59. Thus, when the head restraint assembly 16 is lifted slightly, the shuttle 60 is lifted with it, while the barrel mechanism 50 remains stationary due to the play or spacing within the housing 31 in respect to the barrel mechanism 50, allowing the teeth 61 to be removed from the locking grooves 59 and freeing the head restraint assembly 16 to rotate. The teeth 61 of the shuttle 60 are of a sufficiently small size that slightly lifting the head restraint assembly 16 will remove the teeth 61 from the locking grooves 59. Once the teeth 61 are removed from the locking grooves 59, the head restraint assembly 16 is biased forward by the coiled spring 57a. The barrel mechanism 50 and housing 31 may be biased relative to each other by a biasing

mechanism 90. As shown in FIGURE 1OB, the biasing mechanism 90 is in communication with the housing 31 and the barrel mechanism 50 to bias, via a spring 69, the barrel mechanism 50 towards the shuttle 60 whereby the resting state of the head restraint system 30 is the locked position where the teeth 61 are engaging the locking grooves 59. [0040] As shown in FIGURES 6B and 7, the shuttle 60 is slidably fixed to the head restraint system 30 wherein the shuttle 60 rotates about the barrel mechanism 50 with the head restraint system 30 and is laterally or vertically slidable with respect to the head restraint system 30. As best shown in FIGURE 5, the shuttle 60 has teeth 61 which are adapted to engage the groove portion 51 of the barrel mechanism 50. The shuttle 60 is disposed within the head restraint system 30, and at a first end 63 engages an actuator mechanism 65, described in further detail below, for controllably moving the shuttle 60 from a locked to an unlocked position and vice versa, hi a first position, the shuttle's 60 teeth 61 are located within the locking grooves 59, thus preventing the head restraint 30 from rotating relative to the barrel mechanism 50. hi a second position, the teeth 61 of the shuttle 60 are located outside of the locking grooves 59, such as within the release grooves 58, allowing the head restraint system 30 to rotate relative to the barrel mechanism 50 as the teeth 61 travel along the release grooves 5S. In an exemplary embodiment, a stop (not shown) is provided to prevent rotation of the head restraint system 30 beyond a position where it is substantially parallel with the seat bottom (approximately ninety degrees of rotation) when the seatback 14 is in the upright position.

[0041] hi an exemplary embodiment, best shown in FIGURES 6A, 6B, 8A, 8B, and 9, the head restraint system 30 may be retracted to the storage position by other various methods known in the art, including but not limited to an actuator button mechanism, a release lever, and a pull strap. A number of mechanisms may be used to release and retract the head restraint system 30, such as a solenoid, electric motor, cable, Bowden cable, rope, stop, mechanical linkage, hydraulics, pneumatics, etc.

[0042] hi one embodiment, as best shown in FIGURE 3, an actuator mechanism 65 is provided to actuate the shuttle 60. hi an exemplary embodiment, the actuator mechanism 65 is a side actuator mechanism 65a which is located on the side of the head restraint system 30. The side actuator mechanism 65a (FIGURES 3, 6A and 6B) includes a piston 81a which is in communication with a button 82 at one end 86 and the shuttle 60 at the other end 87a. When the button 82 is depressed, the piston 81a pushes a first end 63 (FIGURE 5) of

the shuttle 60 to slide the teeth 61 of the shuttle 60 from the locking grooves 59 to the release grooves 58.

[0043] In another exemplary embodiment shown in FIGURE 9, the actuator mechanism 65 is a rear actuator mechanism 65b which is located on the second housing 35 (i.e., rear) of the head restraint system 30. The real- actuator mechanism 65b includes a piston 81b which is in communication with a button 82 at one end and with the shuttle 60 at the other end. The piston 81b projects perpendicularly through an aperture 80 in the shuttle 60. The piston 81b has a tapered second end 87b. The tapered second end 87b is engaged by a spring 57 which serves to bias the shuttle 60. When the button 82 is depressed, the tapered second end S7b of the piston SIb compresses the spring 57 and engages the shuttle 60 via the aperture to move the teeth 61 from the locking grooves 59 to the release grooves 58. hi an alternative embodiment, the actuator mechanism 65 may be a bottom actuator mechanism 65c, as best shown in FIGURE 9B. [0044] In another exemplary embodiment, a strap is affixed to the second end 64 of the shuttle 60. When a user pulls the strap way from the head restraint 30, the strap pulls the shuttle 60 from the locked state to the unlocked state to allow the rotation of the head restraint system 30.

[0045] In one exemplary embodiment shown in FIGURE 9, a cable release mechanism 6S is in communication with the seat back 14 whereby the shuttle 60 is actuated when the seatback 14 is folded. The cable release mechanism 68 is affixed at a first end 75 to the seat back 14 and at a second end 76 to the shuttle 60. When the seat back 14 is folded, the cable release mechanism 68 pulls on the shuttle 60, moving the shuttle 60 from a locked state to an unlocked state and allowing the head restraint system 30 to rotate. In one embodiment, the cable release mechanism 68 includes a biasing mechanism 69, such as a spring, to bias the shuttle 60. According to an exemplary embodiment, a single actuation of the cable > release mechanism 68 initiates the folding of head restraint system 30 and the collapse of seat back 14 at approximately the same time.

[0046] According to an exemplary embodiment, the head restraint system 30 rotates inward (i.e., toward the front portion 20 of the seat back 14) along an arc greater than 90° until the front portion 27 of the head restraint system 30 is against the front portion 20 of the seat back 14.

[0047] It is important to note that the construction and arrangement of the elements of the seat assembly 10 provided herein are illustrative only. Although only a few exemplary

embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments (such as variations in the types of seats for which the present invention is incorporated with, sizes, structures, shapes and proportions of the various elements, mounting arrangements, use of materials, combinations of shapes, etc.) without materially departing from the novel teachings and advantages of the invention. For example, the shape of the support posts 36, 38 may be any curvilinear shape that complements an upper portion 22 of a seat back 14 to allow the support posts 36, 38 to be rotated along an arc of substantially 90° or greater without requiring slots to be formed in a front portion 20 of the seat back 14. In addition, the locking grooves 59 and the release grooves 58 of the barrel mechanism 50 have been described in the plural, however one of ordinary skill in the art would recognize that a single groove could be used for each. Further, the present invention is equally applicable to seating systems having a seat back 14 which remains substantially upright and which include a folding head restraint that may be folded down for reasons such as improving visibility throughout a vehicle. Such an application is particularly applicable for rear seats of an automobile where a heightened head restraint may obstruct the driver's rear or side views. Accordingly, all such modifications are intended to be within the scope of the invention. [0048] For purposes of this disclosure, the term "coupled" means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature

[0049] While the present invention has been described in connection with a particularly preferred embodiment thereof, the invention is not to be limited by the drawings. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the

preferred and other exemplary embodiments without departing from the spirit of the inventions as expressed herein.