Kukuruzovic, George (2621 Norfolk Street, Windsor, Ontario N9E 4T7, CA)
Mcmillen, Robert J. (2084 Lesperance Road, Tecsumseh, Ontario N8N 2N4, CA)
Janzen, Larry D. (3918 Third Concession, RR #2 Harrow, Ontario N0R 1G0, CA)
Natanail, Adrian V. (2677 Norfolk Street, Windsor, Ontario N9E 4T8, CA)
Baetens, Eric L. (346 Forest Hill Crescent, Amherstburg, Ontario N9V 4L1, CA)
Colja, Renato (4265 Mount Sinai Cres, Windsor, Ontario N9G 2G7, CA)
Kukuruzovic, George (2621 Norfolk Street, Windsor, Ontario N9E 4T7, CA)
Mcmillen, Robert J. (2084 Lesperance Road, Tecsumseh, Ontario N8N 2N4, CA)
Janzen, Larry D. (3918 Third Concession, RR #2 Harrow, Ontario N0R 1G0, CA)
Natanail, Adrian V. (2677 Norfolk Street, Windsor, Ontario N9E 4T8, CA)
Baetens, Eric L. (346 Forest Hill Crescent, Amherstburg, Ontario N9V 4L1, CA)
| 1. | A lumbar support for a seat, comprising: a belt support; a first bracket connected to one side of said belt support; a second bracket connected to another side of said belt support; a bowden cable comprising an outer sheath and an inner wire, wherein said outer sheath is connected to said first bracket and wherein said inner wire is connected to said second bracket. |
| 2. | A lumbar support according to claim 1, wherein said belt support comprises a panel and a pair of hinged extensions respectively extending between said panel and said first and second brackets. |
| 3. | A lumbar support according to claim 2, wherein said pair of hinged extensions and said first and second brackets restrict said panel from rotating. |
| 4. | A lumbar support according to claim 2, wherein at least one of said pair of hinged extensions comprises an aperture and said bowden cable extends through said aperture. |
| 5. | A lumbar support according to claim 4, wherein at least one of said pair of hinged extensions comprises a tab in front of said bowden cable as it extends through said aperture. |
| 6. | A lumbar support according to claim 2, wherein at least one of said pair of hinged extensions comprises a fitting for said bowden cable. |
| 7. | A lumbar support according to claim 1, wherein said belt support comprises a recessed center channel extending from a top edge of said belt support to a bottom edge of said belt support. |
| 8. | A lumbar support according to claim 1, wherein at least one of said first and second brackets is comprised of a support wire having a center portion between a pair of flexible legs with flared ends. |
| 9. | A lumbar support according to claim 1, wherein said bowden cable wire further comprises a hook, said hook connecting said wire to said second bracket and wherein said bowden cable sheath further comprises a mount, said mount connecting said sheath to said first bracket. |
| 10. | A lumbar support according to claim 11, wherein said sheath ends at said mount and said bowden cable further comprises a sheath segment between said first bracket and said second bracket. |
| 11. | A lumbar support for a seat, comprising: a panel having a recessed center channel bounded by a pair of side plates, wherein said panel further comprises a top edge and a bottom edge and said recessed center channel extends entirely from said top edge to said bottom edge, and wherein said side plates transversely extend from said center channel in an elongated manner. a pair of fixtures attached to said side plates and connecting said panel to opposite sides of the seat; and an actuator operatively connected to at least one of said pair of fixtures. |
| 12. | A lumbar support as set forth in claim 11, wherein said pair of fixtures are further comprised of first and second brackets, each comprised of a support wire having a center portion between a pair of flexible legs with flared ends, and wherein said panel is further comprised of a pair of hinged extensions respectively extending between said side plates and said first and second brackets, and wherein said actuator is further comprised of a bowden cable. |
| 13. | A lumbar support as set forth in claim 12, wherein said hinged extensions are further comprised of a snapfit connection. |
| 14. | A lumbar support as set forth in claim 11, wherein said recessed center channel comprises a plurality of apertures. |
| 15. | A lumbar support as set forth in claim 11, wherein said recessed center channel further comprises a bottom trough between a pair of sloping, faceted sides. |
| 16. | A lumbar support as set forth in claim 15, wherein said apertures form a plurality of concave ribs extending between said pair of side plates transverse to said recessed center channel. |
| 17. | A lumbar support as set forth in claim 16, wherein each of said pair of side plates further comprise a plurality of ridges extending transversely to said channel, wherein said ridges respectively are in line with and connect to said concave ribs. |
| 18. | A lumbar support as set forth in claim 11, wherein said panel further comprises a top extension and a bottom extension, each of which comprise a recessed channel extension bounded by a pair of side extensions. |
| 19. | A lumbar support as set forth in claim 11, wherein said fixtures are selected from the group of connectors consisting of springs, hooks, brackets, clips, wires, and any combination thereof. |
| 20. | A lumbar support as set forth in claim 11, wherein said actuator is comprised of a bowden cable. |
| 21. | A lumbar support for a seat, comprising: a belt support, said belt support comprising a panel, a first hinged extension on one side of said panel, and a second hinged extension on another side of said panel, wherein each of said hinged extensions comprises an aperture; a first bracket connected to said first hinged extension, said first bracket comprising a wire having a center portion between a pair of flexible legs with flared ends; a second bracket connected to said second hinged extension, said second bracket comprising a wire having a center portion between a pair of flexible legs with flared ends; a bowden cable comprising an outer sheath and an inner wire, wherein at least one of said outer sheath and said inner wire extends through said aperture and is connected to one of said brackets. |
| 22. | A lumbar support according to claim 21, wherein said outer sheath is connected to said first bracket and said inner wire is connected to said second bracket. (. |
| 23. | A lumbar support according to claim 21, further comprising a spring extending between said panel and said first bracket through said aperture in said first hinged extension,. |
| 24. | A lumbar support according to claim 23, wherein said outer sheath is connected to said panel by a clip and said inner wire is connected to said second bracket. |
| 25. | A lumbar support according to claim 23, wherein said hinged extension further comprises a tab in front of said spring as it extends through said aperture. |
| 26. | A lumbar support according to claim 21, wherein said panel further comprises a recessed center channel extending from a top edge of said belt support to a bottom edge of said belt support between a pair of planar side plates. |
| 27. | A lumbar support as set forth in claim 26, wherein said recessed center channel comprises a plurality of apertures. |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. App. Nos. 60/632,841, 60/686,579 and 60/733,399, respectively filed on December 3, 2004, June 2, 2005 and November 4, 2005.
BACKGROUND OF THE INVENTION FIELD OF THE INVENTION
[0002] The present invention relates to lumbar supports for seats, and more particularly to seats having a belt-type lumbar support. RELATED ART
[0003] Many different types of strap lumbar supports have been used in seating systems. Strap or belt-type lumbar supports can be any type of strap, including a belt or wire, and are known to be supported in the seat frame by various means, including springs, hooks, brackets, clips, and wires. Strap lumbar supports are also known to be operated using a number of different actuation devices. An example of a prior art belt lumbar support is shown in Figures IA and IB of the accompanying drawings. Other examples of prior art strap lumbar devices can be found in the following references: US 3,258,259, US 3,273,877, US 4,155,592, US 4,309,058, US 4,462,635, US 5,224,757, US 5,482,353, US 5,507,559, US 5,685,606, US 5,716,098, US 5,769,490, US 5,788,328, US 5,797,652, US 5,860,700, US 6,152,531, US 6,254,186, US 6,394,546, US 6,412,868, US 6,471,294, US 6,644,740, US 6,918,634, US 2005/0023873, US 2004/0212227, EP 0296938, EP 0420824, EP 0540481, EP 0518830, EP 0582821, GB526572, FR 2596334, and FR 2765531.
[0004] Strap lumbar devices can usually be distinguished from arching lumbar devices, such as described and illustrated in US 6,003,941 and US 5,518,294, based on the
difference between their respective tensioning elements. The strap lumbar is connected to the seat frame in a manner that the tensioning element must be pulled taut to increase support, and the tensioning element can be the strap itself, as with the belts in US 4,155,592, or another structure, as with the Bowden cable in EP 0296938, or a combination thereof as with support and cables in US 6,152,531. In comparison, the tensioning element in the arching lumbar is stiff and can be rotated, pushed or bowed to increase support. As particularly illustrated in Figure IA and IB, even in the case where the strap lumbar includes a rather stiff belt 2, the belt 2 is connected to a seat frame 6 through a traction cable 4. Increasing tension in the traction cable 4 pulls the belt 2 taut but does not arch the belt 2. As discussed below with reference to the present invention, the preferred traction cable 4 is a Bowden cable 50 which has a sheath 52 surrounding an inner wire core 54 that can slide within the sheath 52.
[0005] In belt lumbar devices, there are a number of different designs for the support elements and their cooperative relationship with the tensioning elements. Many strap lumbar supports are more flexible than the belt lumbar supports. Some supports form a part of the tensioning element and are themselves pulled taut between the seat frame, whereas other supports are merely pressed forward into the seat as the tensioning element is pulled taut.
[0006] Although many prior art devices have adequately provided lumbar support, some problems still remain. As a first example, the spring or cable of the strap-type lumbar support may wear, dig into, or catch upon the seat back foam causing the seat back foam to prematurely fail. As a second example, the belt-type lumbar support may twist or turn during installation or when in use by a seat occupant. The rotation or twisting of the belt-type lumbar support causes difficulty in installation and may cause discomfort to the seat occupant.
[0007] Modular seat assembly techniques require components to be designed for ease and sneed of assembly. Modular lumbar supports often include vertical extensions. In both
assembly and finished use, the extra leverage such extensions place on anchors can cause undesirable wear and binding. Accordingly, along with the need for strong, economical, compact components in seat design, there is a continuing need in seat assembly procedures to increase the economy, speed and efficiency of component assembly and shipping. Furthermore, as described in US Pub. No. 2004/0108760 and US 5,553,919, there is a benefit for providing spinal relief when supporting the spine or for using a shaped pad to provide comfort. It is preferable to apply lumbar supporting pressure bilaterally adjacent to the spinal column, while maintaining a vertical recess or channel to accommodate the vertebrae, because the bony vertebrae of the spine may become uncomfortable if direct pressure is applied to them by a lumbar support pressure surface.
[0008] Therefore, there is a need in the art for an improved belt-type lumbar support that does not affect the wear characteristics of the seat back foam. Further, there is a need in the art for an improved belt-type lumbar support that is rotationally fixed. Additionally, there continues to be a need for strong, economical, compact components that further increase the economy, speed and efficiency of component assembly and shipping. Finally, all of these structural and assembly criteria should be accomplished with the goal of maintaining the comfort of the seat.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention, a seat support includes a panel that is connected to opposite sides of the seat through a pair of fixtures and is operated by an actuator that is connected to at least one of the fixtures. The panel includes a recessed center channel that is bounded by planar side plates. The panel can also include extensions at the top and bottom. According to another aspect of the present invention, the panel has side
extensions at the ends of the side plates that connect the ends of the panel to the seat frame through a bracket. The extensions can include hinges, platforms and/or mounting hooks.
[0010] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0012] Figures IA and IB are views of a prior art design for a belt lumbar.
[0013] Figures 2A and 2B are front and back, perspective views of the belt lumbar according to the present invention, respectively.
[0014] Figure 3A, 3B and 3C are back views of alternative embodiments of the belt lumbar according to the present invention.
[0015] Figures 4A, 4B and 4C are side views of alternative embodiments of the belt lumbar according to the present invention.
[0016] Figure 5 is a perspective view of an embodiment of the belt lumbar with side extensions as installed in a seat frame.
[0017] Figure 6 is a detailed view of the bracket illustrated in Figure 5.
[0018] Figures 7A and 7B are front and back views of the belt lumbar illustrated in Figure 5, respectively.
[0019] Figure 8 is an alternative embodiment of the belt lumbar with side extensions.
[0020] Figure 9 is another alternative embodiment of the belt lumbar with side extensions.
[0021] Figure 10 is a detail view of the belt lumbar attachment.
[0022] Figures 11 and 12 are detailed views of the belt lumbar extensions.
[0023] Figures 13-15 are perspective views of a similar belt lumbar panel with different installation configurations.
[0024] Figures 16 and 17 are perspective views of different belt lumbar combinations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0025] Referring to the accompanying drawings in which like reference numbers indicate like elements, Figures 2A and 2B illustrate perspective views of a belt lumbar 10 according to the present invention. The belt lumbar 10 includes a panel 12, a pair of fixtures 14, and an actuator 16 with a tensioning element connecting the panel 12 to a seat (not shown) through at least one of the fixtures 14. The panel is connected to opposite sides of the seat through the fixtures 14 and can be pulled taut in the seat by the actuator or the tensioning element of the actuator may be pulled taut to force the panel 12 forward into the seat.
[0026] The panel 12 includes a recessed center channel 18 that is bounded by planar side plates 20 and may include apertures 22 extending across the channel. The recessed center channel 18 has a bottom trough 24 between a pair of sloping, faceted sides 26, and can be formed by concave ribs 30 that extend between the pair of side plates 20, i.e. extending transverse to the recessed center channel 18 and separated by the apertures 22. As particularly illustrated in Figure 2, the side plates 20 are preferably formed with ridges 28 that are in line with and connect to the concave ribs 30. The ridges 28 extend transversely to the channel 18.
[0027] The faceted sides 26 of the recessed center channel 18 are separated by a distance D. In the depicted embodiment, the faceted sides 26 are preferably separated by at least 30mm. The side plates 20 extend transversely on either side of the recessed center channel 18 in an elongated manner, i.e. the side plates 20 are more than twice as wide in comparison to the recessed center channel 18 or more than twice as wide as the distance D.
[0028] The size of the ridges 28 can be changed, increased or decreased, to vary the stiffness of the panel 12 in the direction transverse to the channel 18. The size of the apertures 22, i.e. width and spacing of the ribs 30, can also be varied to alter the stiffness of the panel 12 along the axis of the channel 18. It will also be appreciated that the number and size of the finger extensions 32 can also be varied to change the size of the support region. Generally, the side panels are more stiff or rigid in comparison with the channel 18.
[0029] The recessed center channel 18 preferably extends entirely along the length of the panel's centerline, from a top edge 34 to a bottom edge 36 shown in each of the preferred embodiments, as particularly illustrated in Figures 3A, 3B and 3C. In Figure 3A, the pair of side plates 20 and top and bottom ribs 30 form a panel 12 with straight top and bottom edges 34, 36. As illustrated in Figures 3B and 3C, the panel 12 could also have a top extension 38 and a bottom extension 40. In each of these embodiments, either one or both of these top and bottom extensions 38, 40 may also have side plates 20. These side plates 20 may also have flexible projections (or fingers) 32 extending transversely to the recessed channel 18 and in line with the concave ribs 30.
[0030] It will be appreciated that the panel 12 can be attached to a seat frame (not shown) through springs, hooks, brackets, clips, wires, and any other equivalent fastener or connector hardware. In the preferred embodiment, the tensioning element of the actuator 16 is a Bowden cable 50 which has a sheath 52 surrounding an inner wire core 54 that can slide within the sheath 52. The actuator 16 can be operated by a manual device, such as a hand
wheel or lever, or by a powered device, such as an electric motor and gear assembly. The sheath 52 is attached to the panel 12 by a clip 60 and the wire core 54 extends to the connector 14.
[0031] As illustrated in Figures 4A, 4B and 4C, the panel 12 can be formed with different support profiles. The panel 12 in Figure 4A is relatively flat, whereas the panels 12 in Figures 4B and 4C are arcuate, having an arc and a three-fold curve. Each of the panels in Figures 4A, 4B and 4C are similar in that they are substantially planar as they extend transversely from the recessed center channel 18.
[0032] From the prior art devices, it will be appreciated that there are a number of ways to connect the panel 12 to the seat frame 6 and provide tension thereto by one or more actuators 16. For example, as with US 6,152,531, the panel may be mounted to the frame through springs or other brackets and may have a tensioning element on each side of the panel. Alternatively, the Bowden cable may extend behind the panel from one side to the other, such as in EP 0296938. For the embodiments described above, it will be particularly noted that there is a clip 60 on each side of the panel 12 which can accommodate the sheath 52 for a Bowden cable that extends behind the panel 12 or for an actuator 16 on each side of the panel 12. As discussed below, there are additional ways to connect the panel 12 to the seat frame 6 that differ from known devices.
[0033] As with the panels 12 described in detail above with reference to Figures 2-4, the embodiments described below also preferably have panels 12 formed with a recessed center channel 18. However, the embodiments in Figures 2-4 do not have any side extensions which would, during assembly, prevent the panel from rotating within the seat frame or maintain the panel in a fixed position within the seat frame. In comparison, the embodiments described below with reference to Figures 5-9 have side extensions 62 that maintain the panel 12 within the seat frame 6 and restrain the panel 12 against rotation.
[0034] As illustrated in Figure 5, the belt support 10 can be connected to the seat frame 6 through a pair of brackets 64 at opposite sides of the belt support 10, and a Bowden cable 50 that is also connected between the brackets 64. The belt support 10 includes the panel 12 and the pair of side extensions 62 that respectively extend between the panel 12 and the brackets 64 which hold the lumbar support 10 within the seat frame. The side extensions 62 are preferably in the form of hinged extensions 66 that are discussed in more detail below. As discussed above, the panel 12 preferably includes a center recessed channel 18 between a pair of side plates 20, and the hinged extensions 66 and the brackets 64 restrict said panel 12 from rotating.
[0035] As particularly illustrated in Figure 6, the brackets 64 are preferably formed by a u-shaped support wire 68. The hinged extensions 66 connect to the brackets 64 at the center portion 70 of the u-shaped wire. A leg portion 72 with a flared end 74 is at each end of the center portion 70. The legs 72 can flex 76 to permit the flared ends 74 to fit into lance tabs 78 in the seat frame 6. The center portion 70 may be angled and can provide flexibility to the bracket 64 in a spring-like manner.
[0036] Figures 7 A and 7B demonstrate the modular nature of the lumbar support 10 for assembly operations. The actuator 16 is directly attached to the panel 12 and the brackets 64 are fitted into the ends of the side extensions 62, with the Bowden cable 50 extending therebetween. With this configuration, the entire lumbar support 10 can be installed as a unit within the seat frame 6 by merely fitting the flared ends 74 into the lance tabs 78 and connecting the actuator 16 to its source for power and control. Once installed, as the wire 54 in the Bowden cable 50 is pulled through the sheath 52, the tension in the Bowden cable 50 increases and as it becomes taut, thereby forcing the panel 12 forward in the seat frame 6.
[0037] The hinged extensions 66 preferably include a central aperture 80 through which the Bowden cable 50 extends and fittings for the Bowden cable sheath 52 and cable
54. In particular, at the end of one of the side extensions 62, there is a mount 82 which holds the end of the sheath 52 in place. The mount 82 is preferably held in place on the side extension by a snap-fit connection 84, which can also be an indentation or a groove for a form fit connection. Similarly, at the end of the other side extension 62, a snap fit connection 84 is preferably used as the fitting for a hook 86 at the end of the wire 54. The sheath 52 that extends from the actuator 16 ends at the mount 82, but as particularly illustrated in Figure 7B, a sheath segment 84 may also extend between the brackets.
[0038] Figures 8 and 9 illustrate alternative attachment configurations for hinged extensions 66 with an optional tab 88 in front of the aperture 80. In these configurations, the sheath 52 is connected to the side plate 20 on one .side of the recessed center channel 18, with the wire 54 extending behind the tab 88 and through the aperture 80, and a spring 90 is connected to the other side plate 20 on the other side of the recessed center channel 18. Similar to the wire 54, the spring 90 extends through the aperture 80 and connects to the ends of the side extensions 62. With the tab 88 in front of the aperture 80, the padding at the front of the seat (not shown) is less likely to get caught, worn or torn by the hinged extensions 66, the spring 90 or the wire 54 as the panel 12 moves forward in the seat frame and pushes against the padding and the hinged extensions 66 close.
[0039] The hinged extensions 66 can be integrally formed with the panel 12, as in Figure 8, or fastened to the side plates 20, as in Figure 9. Also, the tab 88 can extend over the aperture 80 outwardly from the side plates 20 or inwardly from the ends of the hinged extensions 66. In the prior art, U.S. Patent No. 5,716,098 discloses a flexible hinge with a tongue and slot arrangement. However, the tongue and slot are in a different orientation and relative relationship with respect to the belt and each other. In particular, the flexible hinge in the prior art is not formed as a hinge extension to the belt and does not have an aperture. In nnmnarison, U.S. Patent No. 5,769,490 discloses another type of a flexible hinge which can
distort in an elastic manner. This type of flexible hinge is not formed as an extension at the end of the belt but is instead formed between the ends of the belt and also does not have an aperture as in the present invention. Even though the hinge extensions 66 of the present invention preferably have a pre-formed curvature 92 to provide more area for the aperture 80, it is possible that each end of the belt lumbar 10 could use a pair of elastic-type flexible hinges without any such pre-formed curvature such that an aperture is formed between the flexible hinges. It is also possible for a living hinge to be used for the hinge extension 66, in which case the angles in the pre-formed curvature 92 would preferably be thinner in cross- section than the side plates 20. As discussed above, the hinge extension 66 permits the panel 12 to move toward or away from a seat occupant but significantly reduces the ability of the panel 12 to twist or rotate between the frame 6. Therefore, in comparison with these prior art references, by using the hinge extensions 66, the present invention serves to reduce any rotation or twisting of the panel 12 between the frame 6, whereas the single flexible hinge designs are designed to permit the rotation or twisting of the belt lumbar.
[0040] As generally illustrated in Figures 8 and 9 and particularly illustrated in Figure 10, the side plates 20 can also contain a pocket 94. The pocket 94 includes a slot 96 to receive an end of the spring 90. The pocket 94 may also be reinforced, such as with additional material in this region or by an insert 98 of plastic or metal. As also illustrated in Figure 10, the hinged extensions 66 are preferably formed with a clip 100 at the end to secure the panel 12 to the brackets 64. Preferably, the clip 100 has a hooked end that fits snugly over the center portion 70 of the u-shaped support wire 68.
[0041] Figures 11 and 12 compare the differences between the preferred hinge extension 66 that connects the panel 12 to the bracket to prevent rotation or twisting and an straight extension 102 that permits the panel to rotate and twist. Figures HA and HB respectively show the front and back views of the hinge extension 66, and Figures 12 A and
12 B respectively show the front and back views of the straight extension 102. Each type of extension 66, 102 includes the tab 88 in front of the aperture 80 to prevent the padding from getting caught, worn or torn by the spring 90 or the wire 54 as the panel 12 moves forward in the seat frame. Additionally, each of these extensions 66, 102 includes a clip 100 and snap- fit connections 84. However, the straight extension 102 does not connect the panel to the bracket. Instead, the panel 12 is only connected to the brackets through the Bowden cable. Of course, as with the lumbar system disclosed by EP 0296938, additional springs or brackets could connect the panel to the seat frame apart from the tension cable.
[0042] Figures 13-15 each show a belt lumbar 10 with different installation configurations. Each one of the installations uses a panel 12 similar to the one described above with reference to Figure 3B. In Figure 13, the belt lumbar 10 has a panel 12 without any extensions and a manually-operated actuator 104 is used to provide tension to the Bowden cable. In Figure 14, the belt lumbar 10 has hinged extensions 66 connecting the ends of the panel 12 with the brackets, and this configuration also has a manually-operated actuator 104. In Figure 15, the belt lumbar 10 has hinged extensions 66 and has a power- operated actuator 106.
[0043] Figures 16 and 17 are perspective views of different belt lumbar combinations according to the present invention. In Figure 16, there are two panels 12 that are spaced horizontally with respect to each other, and each has its own actuator 16. In Figure 17, there is a single panel 16 that has horizontally-spaced actuators. The single panel may actually be a pair of panels that are horizontally adjacent to each other.
[0044] As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting.
Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
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