Seat recliner mechanism with spring coil actuator and redundant positioning

Claim 2

A seat recliner mechanism for supporting a seat back and a seat bottom which permits the angle therebetween to be controllably varied comprising: a lower recliner structure supporting said seat bottom, an upper recliner structure supporting said seat back, a first pivot rotatably attaching said lower recliner structure to said upper recliner structure, a toothed rack operatively connected to one of said upper or lower recliner structures, gear means carried by the other of said upper or lower recliner structures for engaging said toothed rack and controlling the positioning of said toothed rack, an actuator clutch drum carried by the other of said upper or lower recliner structures and rotatably driven by said gear means, a unitary coil clutch spring wrapping around said actuator clutch drum, said coil clutch spring having first and second spring ends, first spring engaging means carried by the other of said upper or lower recliner structures for engaging said first spring end, second spring engaging means carried by the other of said upper or lower recliner structures for engaging said second spring end, and actuation means carried by the other of said upper or lower recliner structures for producing relative movement between said first and second spring engaging means thereby moving said first and second spring ends from an engaged position in which said coil clutch spring frictionally engages said clutch drum such that said first spring engaging means restrains rotation of said actuator clutch drum in a first rotational sense and said second spring engaging means restrains rotation of said clutch drum in a second rotational sense wherein the relative angular positioning between said lower and upper recliner structures is established, to a disengaged position in which said coil clutch spring frictionally disengages said actuator clutch drum wherein the relative angular positioning between said lower and upper recliner structures is adjustable.

Claim 3

The seat recliner mechanism according to claim 1 wherein said toothed rack is operatively connected to said upper recliner structure and said gear means, and wherein said actuator clutch drum, said coil clutch spring, said first and second spring engaging means and said actuation means are carried by said lower recliner structure.

Claim 4

The seat recliner mechanism according to claim 1 wherein said toothed rack is formed by a quadrant which controls relative positioning between said upper and lower recliner structures.

Claim 5

The seat recliner mechanism according to claim 1 wherein said gear means comprises a gear transmission which produces a torque level applied to said actuator clutch drum which is less than that applied to said gear means by said toothed rack.

Claim 6

The seat recliner mechanism according to claim 1 wherein said gear means comprises at least a first gear having gear sections of differing diameters, one of said gear sections meshing with said toothed rack and another of said gear sections meshing with an actuator clutch drive gear which rotates with said actuator clutch drum, said first gear engaging with said toothed rack and said actuator clutch drive gear to provide a gear transmission which produces a torque level applied to said actuator clutch drum which is less than that applied to said first gear by said toothed rack.

Claim 7

The seat recliner mechanism according to claim 1 wherein said gear means comprises a first gear having a small gear section and a large gear section, said first gear small gear section meshing with said toothed rack, a second gear having a small gear section and a large gear section, said second gear small gear section meshing with said first gear large gear section, and further comprising an actuator clutch drive gear which rotates with said actuator clutch drum, said drive gear meshing with said second gear large diameter section.

Claim 8

The seat recliner mechanism according to claim 1 wherein rotational biasing torque is applied to said upper recliner structure by a torsion spring acting on said gear means.

Claim 9

The seat recliner mechanism according to claim 1 wherein said first spring engaging means comprises a first cam plate which engages said first spring end and defines a cam slot, said second spring engaging means comprising a second cam plate which engages said second spring end and defines a cam slot, said actuation means comprising an actuation lever movable to cause movement of a drive pin, wherein said drive pin interacts with said cam slots to move said coil clutch spring between said engaged and disengaged positions.

Claim 10

The seat recliner mechanism according to claim 8 wherein said cam slots are oriented and dimensioned such that said drive pin engages said first cam plate while being disengaged from said second cam plate when said rotation force in said first rotational direction is acting upon said actuator clutch drum whereas said drive pin engages said second cam plate while being disengaged from said first cam plate when said rotational force in said second rotational direction is acting upon said actuator clutch drum.

Claim 11

The seat recliner mechanism according to claim 8 wherein said first and second cam plates are rotatable about the axis of rotation of said actuator clutch drum.

Claim 12

The seat recliner mechanism according to claim 8 wherein said cam slots provide lost motion of said cam plates when said cam plates are moved to a position causing said coil clutch spring to frictionally engage said actuator clutch drum.

Claim 13

The seat recliner mechanism according to claim 8 wherein said coil clutch spring first and second ends are engaged with said actuator cam plates by trapping between rivets and said actuator cam plates.

Claim 14

The seat recliner mechanism according to claim 1 further comprising redundant positioning means responsive to the positioning of said actuation means for preventing unrestrained angular displacement of said upper recliner structure with respect to said lower recliner structure in the event of failure of said coil clutch spring to fix the angular positioning between said lower and upper recliner structures.

Claim 15

The seat recliner mechanism according to claim 8 further comprising redundant positioning means for preventing unrestrained angular displacement of said upper recliner structure with respect to said lower recliner structure in the event of failure of said coil clutch spring to fix the angular positioning between said lower and upper recliner structures, wherein said redundant positioning means includes a redundant positioning pawl movable between positions of engagement and disengagement with said toothed rack, and a redundant positioning lever interacting with said drive pin and said redundant positioning pawl to move said pawl between said positions in response to movement of said actuation lever.

Claim 16

The seat recliner mechanism according to claim 1 wherein said coil clutch spring normally wraps tightly around said actuator clutch drum whereby said actuation means does not forceably position said coil clutch spring means ends to said engaged position.

Claim 17

A seat recliner mechanism supporting a seat back and a seat bottom which permits the angle therebetween to be controllably varied comprising: a lower recliner structure supporting said seat bottom, an upper recliner structure supporting said seat back, a first pivot rotatably attaching said lower recliner structure to said upper recliner structure, a toothed rack operatively connected to said upper recliner structure, a first gear carried by said lower recliner structure meshing with said toothed rack, a second gear carried by said lower recliner structure meshing with said first gear, a coil spring clutch actuator including an actuator clutch drum carried by said lower recliner structure, an actuator clutch drum drive gear meshing with said second gear, said first gear second gear and said actuator clutch drive gear providing a gear transmission which produces a torque applied to said actuator clutch drum which is less than that applied to said first gear by said toothed rack, and a coil clutch spring wrapping around said actuator clutch drum, said coil clutch spring having first and second extending ends, first and second cam plates rotatable about the axis of rotation of said actuator clutch drum, said actuator cam plates each having spring engaging arms for engaging said coil clutch spring ends and having actuator lever arms defining cam surfaces, a movable actuation lever having a drive pin which interacts with said actuator lever arm cam surfaces to move said actuator cam plates between positions of frictional engagement and disengagement of said coil clutch spring with said actuator clutch drum, and a redundant positioning pawl movable between positions of engagement and disengagement with said toothed rack in response to movement of said actuator lever for restraining angular movement of said upper recliner structure with respect to said lower recliner structure in the event of failure or improper operation of said coil spring clutch actuator.

Claim 18

A seat recliner mechanism supporting a seat back and a seat bottom which permits the angle therebetween to be controllably varied comprising: a lower recliner structure supporting said seat bottom, an upper recliner structure supporting said seat back, a first pivot rotatably attaching said lower recliner structure to said upper recliner structure, a toothed rack operatively connected to said upper recliner structure, a first gear carried by said lower recliner structure meshing with said toothed rack, a second gear carried by said lower recliner structure meshing with said first gear, a coil spring clutch actuator including an actuator clutch drum carried by said lower recliner structure, an actuator clutch drum drive gear meshing with said second gear, said first gear second gear and said actuator clutch drive gear providing a gear transmission which produces a torque applied to said actuator clutch drum which is less than that applied to said first gear by said toothed rack, and a coil clutch spring wrapping around said actuator clutch drum, said coil clutch spring having first and second extending ends, first and second cam plates rotatable about the axis of rotation of said actuator clutch drum, said actuator cam plates each having spring engaging arms for engaging said coil clutch spring ends and having actuator lever arms defining cam surfaces, a movable actuation lever having a drive pin which interacts with said actuator lever arm cam surfaces to move said actuator cam plates between positions of frictional engagement and disengagement of said coil clutch spring with said actuator clutch drum, and a redundant positioning pawl movable between positions of engagement and disengagement with said toothed rack in response to movement of said actuator lever for restraining angular movement of said upper recliner structure with respect to said lower recliner structure in the event of failure or improper operation of said coil spring clutch actuator.

Claim 19

The seat recliner mechanism according to claim 16 wherein said toothed rack is formed by a quadrant which controls relative positioning between said upper and lower recliner structures.

Claim 20

The seat recliner mechanism according to claim 16 wherein said first gear having a small gear section and a large gear section, said first gear small gear section meshing with said toothed rack, said second gear having a small gear section and a large gear section, said second gear small gear section meshing with said first gear large gear section said second gear large gear section meshing with said actuator clutch drum drive gear.

Claim 21

The seat recliner mechanism according to claim 16 wherein rotational biasing torque is applied to said upper recliner structure by a spring acting on said gear means.

Claim 22

The seat recliner mechanism according to claim 16 wherein said cam slots provide lost motion of said actuator cam plates when said cam plates are moved to a position causing said coil clutch spring to frictionally engage said clutch drum.

Claim 23

The seat recliner mechanism according to claim 16 wherein said coil clutch spring ends are engaged with said actuator cam plates by trapping between a rivet and said actuator cam plates.

Claim 24

The seat recliner mechanism according to claim 15 wherein said coil clutch spring normally wraps tightly around said actuator clutch drum whereby said actuation means does not forceably position said coil clutch spring ends to said engaged position.