U.S. patent application number 10/662946 was filed with the patent office on 2004-12-09 for apparatus and method for lumbar support with variable apex.
This patent application is currently assigned to L & P Property Management Company. Invention is credited to McMillen, Robert J..
Application Number | 20040245824 10/662946 |
Document ID | / |
Family ID | 21707685 |
Filed Date | 2004-12-09 |
United States Patent
Application |
20040245824 |
Kind Code |
A1 |
McMillen, Robert J. |
December 9, 2004 |
Apparatus and method for lumbar support with variable apex
Abstract
A lumbar support to be installed in a seat has an apex that
varies vertically along a guide rail. The said guide rail has an
upper stop and a lower stop. A bowing element disposed on the guide
rail travels in a substantially vertical plane. A first bowden
cable draws an upper portion of the bowing element downward until a
lower portion of the bowing element is in abutment with the lower
stop such that a low convexity is formed in the bowing element as
the bowden cable continues to draw the upper portion of said bowing
element further towards said lower stop. A second bowden cable
draws a lower portion of the bowing element upward until the upper
portion of the bowing element is in abutment with the upper stop
and such that a high convexity is formed in the bowing element as
the bowing element continues to draw said lower portion of the
bowing element further towards the upper stop.
Inventors: |
McMillen, Robert J.;
(Tecumseh, CA) |
Correspondence
Address: |
HUSCH & EPPENBERGER, LLC
190 CARONDELET PLAZA
SUITE 600
ST. LOUIS
MO
63105-3441
US
|
Assignee: |
L & P Property Management
Company
4095 Firestone Boulevard
South Gate
CA
90280
|
Family ID: |
21707685 |
Appl. No.: |
10/662946 |
Filed: |
September 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10662946 |
Sep 15, 2003 |
|
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10003803 |
Nov 2, 2001 |
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6652028 |
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Current U.S.
Class: |
297/284.4 ;
297/284.1 |
Current CPC
Class: |
B60N 2/0228 20130101;
B60N 2/6673 20150401; B60N 2/666 20150401; B60N 2/6671 20150401;
B60N 2/0232 20130101 |
Class at
Publication: |
297/284.4 ;
297/284.1 |
International
Class: |
A47C 003/025 |
Claims
What is claimed is:
1. A lumbar support with a variable apex comprising: at least one
guide element adapted to be disposed within a seat, said guide
element having an upper stop and a lower stop; a bowing element
disposed to travel on said guide element, said bowing element
having an upper portion and a lower portion; a first traction
element operatively engaged to draw said upper portion of said
bowing element toward said lower portion of said bowing element
such that said lower portion of said bowing element is drawn into
abutment with said lower stop and such that a first convexity is
formed in said bowing element as said traction element continues to
draw said upper portion of said bowing element further towards said
lower stop; and a second traction element operatively engaged to
draw said lower portion of said bowing element toward said upper
portion of said bowing element such that said upper portion of said
bowing element is drawn into abutment with said upper stop and such
that a second convexity is formed in said bowing element as said
traction element continues to draw said lower portion of said
bowing element further towards said upper stop.
2. The lumbar support of claim 1 wherein said bowing element
travels in a substantially vertical plane.
3. A lumbar support with an apex that travels vertically
comprising: at least one guide element adapted to be disposed
within a seat, said guide element having an upper stop and a lower
stop; a bowing element disposed to travel on said guide element,
said bowing element having an upper portion and a lower portion; a
mount attached to said guide element between said upper stop and
said lower stop; and at least one traction element operatively
engaged to draw one of said upper portion or said lower portion of
said bowing element toward said mount such that the other of said
upper portion or said lower portion of said bowing element is drawn
into abutment with one of said upper stop or said lower stop and
such that a convexity is formed in said bowing element as said
traction element continues to draw one of said upper portion or
said lower portion further towards said mount.
4. The lumbar support of claim 3 wherein said bowing element
travels in a substantially vertical plane.
5. A lumbar support with variable apex height comprising: at least
one guide rail having a top stop and a bottom stop and having a
central bracket; an archable pressure surface slidingly disposed on
said guide rail, said archable pressure surface having an upper
portion and a lower portion, said upper portion and lower portion
being closer together than said top stop and said bottom stop of
said guide rail when said archable pressure surface is arched; a
first bowden cable having a first sleeve anchored to said upper
portion of said archable pressure service and said first bowden
cable having a first wire slidingly disposed within said first
sleeve, said first wire being anchored to said central bracket of
said guide rail such that when said first wire of said first bowden
cable is drawn into said first sleeve of said first bowden cable, a
downward traction on said archable pressure surface is stopped by
said bottom stop of said guide rail and a low arch is formed; and a
second bowden cable having a second sleeve anchored to said lower
portion of said archable pressure surface and said second bowden
cable having a second wire slidingly disposed within said second
sleeve, said second wire being anchored to said central bracket of
said guide rail such that when second said second wire is drawn
into said second sleeve of said second bowden cable, an upward
traction on said archable pressure surface is stopped by said top
stop of said guide rail and a high arch is formed.
6. The lumbar support of claim 5 wherein at least one of said first
or second sleeves are anchored to said upper portion or said lower
portion of said archable pressure surface via a spring.
7. The lumbar support of claim 5 wherein said first bowden cable
and said second bowden cable are opposing ends of a single bowden
cable.
8. The lumbar support of claim 5 further comprising an actuator
being engaged with said first bowden cable and said actuator being
engaged with said second bowden cable such that activation of said
actuator in a first direction draws said first wire into said first
sleeve and activation of said actuator in a second direction draws
said second wire into said second sleeve.
9. The lumbar support of claim 8 wherein said actuator is a
rotating actuator and said activation is rotation.
10. The lumbar support of claim 8 wherein said actuator is
activated by an electric motor.
11. The lumbar support of claim 5 wherein said archable pressure
surface is further comprised of: at least two mounting brackets,
each slidingly disposed on said guide rail between said upper stop
and said lower stop, each of said mounting brackets having a bowden
cable sleeve anchor and each of said mounting brackets having at
least two concavities; at least two flexible pressure rods having
two ends, each of said ends being pivotally engaged with said
concavities; and a plurality of lateral wires attached to each of
said flexible pressure rods.
12. The lumbar support of claim 5 further comprising a
vibrator.
13. A lumbar support with a high apex and a low apex comprising: at
least one guide rail having at least one upper stop and at least
one lower stop and having a central bracket between said upper stop
and lower stop; an upper mounting bracket and a lower mounting
bracket, each slidingly disposed on said at least one guide rail;
at least two flexible pressure rods each having an upper end
pivotally attached to said upper mounting bracket and a lower end
pivotally attached to said lower mounting bracket; a plurality of
wires each attached to each of said at least two flexible pressure
rods; a first bowden cable having a first sleeve and a first wire,
said upper mounting bracket being attached to one or the other of
said first sleeve or first wire of said first bowden cable and said
central bracket being attached to the other of said first sleeve or
said first wire of said first bowden cable such that traction of
said first bowden cable draws said upper mounting bracket towards
said central bracket, whereby said lower mounting bracket it drawn
into abutment with said lower stop of said guide rail and said at
least two flexible pressure rods bow outward; and a second bowden
cable having a second sleeve and a second wire, said lower mounting
bracket being attached to one or the other of said second sleeve or
said second wire of said second bowden cable and said central
bracket being attached to the other of said second sleeve or said
second wire of said second bowden cable such that traction of said
second bowden cable draws said lower mounting bracket towards said
central bracket whereby said upper mounting bracket is drawn into
abutment with said upper stop of said guide rail and said at least
two flexible rods bow outward.
14. A lumbar support with variable apex height comprising: at least
one guide rail having a top stop and a bottom stop and having a
central bracket; an archable pressure surface slidingly disposed on
said guide rail, said archable pressure surface having an upper
portion and a lower portion, said upper portion and lower portion
being closer together than said top stop and said bottom stop of
said guide rail when said archable pressure surface is arched; a
first bowden cable having a first sleeve anchored to said upper
portion of said archable pressure service and said first bowden
cable having a first wire slidingly disposed within said first
sleeve, said first wire being anchored to said central bracket of
said guide rail such that when said first wire of said first bowden
cable is drawn into said first sleeve of said first bowden cable, a
downward traction on said archable pressure surface is stopped by
said bottom stop of said guide rail and a low arch is formed; a
second bowden cable having a second sleeve anchored to said lower
portion of said archable pressure surface and said second bowden
cable having a second wire slidingly disposed within said second
sleeve, said second wire being anchored to said central bracket of
said guide rail such that when second said second wire is drawn
into said second sleeve of said second bowden cable, an upward
traction on said archable pressure surface is stopped by said top
stop of said guide rail and a high arch is formed; an electric
motor operatively engaged to each of said first and second bowden
cables to draw said bowden cable wires into said bowden cable
sleeves; and a processor operatively engaged to control said
electric motor, said processor being programmed to automatically
draw said first wire into said first sleeve of said first bowden
cable, such that a downward traction on said archable pressure
surface is stopped by said bottom stop of said guide rail and a low
arch is formed and then draw said second wire into said second
sleeve of said second bowden cable, such that an upward traction on
said archable pressure surface is stopped by said top stop of said
guide rail and a high arch is formed.
15. The lumbar support of claim 14 wherein said processor is
further programmed to repeat said automatic drawing of said first
bowden cable and said second bowden cable, said repetition
continuing for a pre-configured time.
16. A lumbar support with variable apex height comprising: at least
one guide rail having a top stop and a bottom stop and having a
central bracket; an archable pressure surface slidingly disposed on
said guide rail, said archable pressure surface having an upper
portion and a lower portion, said upper portion and lower portion
being closer together than said top stop and said bottom stop of
said guide rail when said archable pressure surface is arched; a
first bowden cable having a first sleeve anchored to said upper
portion of said archable pressure service and said first bowden
cable having a first wire slidingly disposed within said first
sleeve, said first wire being anchored to said central bracket of
said guide rail such that when said first wire of said first bowden
cable is drawn into said first sleeve of said first bowden cable, a
downward traction on said archable pressure surface is stopped by
said bottom stop of said guide rail and a low arch is formed; a
second bowden cable having a second sleeve anchored to said lower
portion of said archable pressure surface and said second bowden
cable having a second wire slidingly disposed within said second
sleeve, said second wire being anchored to said central bracket of
said guide rail such that when second said second wire is drawn
into said second sleeve of said second bowden cable, an upward
traction on said archable pressure surface is stopped by said top
stop of said guide rail and a high arch is formed; an actuator
housing anchoring each of said first and second sleeves of said
first and second bowden cables; an actuator wheel disposed within
said actuator housing, said actuator wheel being operatively
engaged to each of said first and second wires of said first and
second bowden cables such that rotation of said actuator wheel in a
first direction draws said first wire into said first sleeve of
said first bowden cable, and rotation of said actuator wheel in a
second direction draws said second wire into said second sleeve of
said second bowden cable, an electric motor operatively engaged to
said actuator wheel; and a processor operatively engaged to control
said electric motor, said processor being programmed to
automatically draw said first wire into said first sleeve of said
first bowden cable, such that a downward traction on said archable
pressure surface is stopped by said bottom stop of said guide rail
and a low arch is formed and then draw said second wire into said
second sleeve of said second bowden cable, such that an upward
traction on said archable pressure surface is stopped by said top
stop of said guide rail and a high arch is formed.
17. The lumbar support of claim 14 wherein said processor is
further programmed to repeat said automatic drawing of said first
bowden cable and said second bowden cable, said repetition
continuing for a pre-configured time.
18. The lumbar support of claim 14 further comprising a
vibrator.
19. A method of assembling an ergonomic support that has two apexes
comprising: constraining a travel path of an archable pressure
surface between an upper stop and a lower stop of a guide element;
disposing said archable pressure surface flat on said guide element
between said upper stop and said lower stop; fixing a first
traction element to a first half of said archable pressure surface
such that traction on said first traction element draws said first
half of said archable pressure surface toward said upper stop to
create an upper apex in said archable pressure surface; and fixing
a second traction element to a second half of said archable
pressure surface such that traction on said second traction element
draws said second half of said archable pressure surface toward
said lower stop to create a lower apex in said archable pressure
surface.
20. The method of claim 19 wherein said travel path of said
archable pressure surface is substantially vertical.
21. The method of claim 19 wherein said traction element is a
bowden cable.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] None.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The method and apparatus of the present invention is in the
field of lumbar supports having arched apexes that can be varied in
height.
[0005] 2. Prior Art
[0006] Lumbar supports that have archable pressure surfaces
actuated by traction cables are known. Typically a flexible
pressure surface is mounted on guide rails with a bowden cable
sleeve attached to one end of the pressure surface and the bowden
cable wire attached to the other end. Traction drawing the wire
into the sleeve draws the two ends of the flexible surface together
arching it towards a seat occupant. These simple devices are unable
to raise or lower the apex of the arch created in a significant or
controllable manner.
[0007] Lumbar supports with arching pressure surfaces that can move
the apes of the arch vertically are expensive, complex and bulky.
Typically the vertical movement (and usually the arching movement
as well) are actuated by electric motors, as in U.S. Pat. No.
5,050,930 to Schuster, et al. and U.S. Pat. No. 5,609,394 to Ligon,
Sr. et al. The ability of these units to customize the vertical
alignment of an apex arch to an individual users preference are
desirable in the market place. However, the size of these units
limits the ability to install other devices, such as duct work, in
a seat, their complexity decreases their durability and their
expense limits their marketability to luxury vehicles.
[0008] There is a need in the art for a simple, durable, compact
and inexpensive lumbar support capable of varying the apex of it's
arch vertically.
SUMMARY OF THE INVENTION
[0009] The present invention is a lumbar support that has an
archable pressure surface with a vertically variable apex. A
flexible, archable pressure surface has a top end and a bottom end,
each of which are slidingly mounted on a pair of guide rails. The
guide rails have end stops which prevent the archable pressure
surface to slide beyond the stops. When the archable pressure
surface is flat, the distance between the sliding ends of the
archable pressure surface is substantially equal to the distance
between the guide rail end stops.
[0010] However, when the pressure surface is arched, the distance
between the sliding ends of the pressure surface is shorter than
the distance between the guide rail end stops. The present
invention takes advantage of this gap between an arched pressure
surface and the guide rail stops in order to move the arched
pressure surface, and it's apex, up and down.
[0011] The guide rails have a mounting bracket which does not move
that is substantially half way between the guide rail end stops.
The present invention is capable of arching it's pressure surface
with not one, but either of two bowden cables used to apply the
traction that draws the pressure surface top and bottom ends
towards one another.
[0012] A top bowden cable has it's sleeve anchored at the pressure
surface top end and it's axial sliding wire anchored at the center
bracket. A second, bottom bowden cable has it's sleeve anchored to
the bottom of the archable pressure surface and it's sliding axial
wire anchored to the central mounting bracket. Traction drawing the
bowden cable wire into the bowden cable sleeve on either of these
bowden cables will shorten the distance between the top and bottom
ends of the pressure surface, bowing it outwards and creating an
arch.
[0013] If traction is applied to the top bowden cable, the bowden
cable sleeve end draws the top of the archable pressure surface
downwards towards the central bracket. This also draws the opposing
bottom of the archable pressure surface downwards, where it is
stopped by the bottom guide rail stop. Continuing traction draws
the pressure surface top end closer to the stopped pressure surface
bottom end, causing it to flex outwards. Conversely, traction on
the bottom bowden cable draws the bottom of the archable pressure
surface towards where the bottom bowden cable wire is mounted on
the central bracket. The top of the archable pressure surface is
stopped by the top guide rail stop and continuing pressure on the
bottom bowden cable pinches the archable pressure surface between
the bottom bowden cable sleeve and the top guide rail stop, again
flexing the archable pressure surface.
[0014] The dimensions of the arch created by these motions is the
same if either the top or bottom bowden cable are used to create
it. If the top bowden cable is used to create the arch, the arch
will be butting the bottom guide rail stop, and if the bottom
bowden cable is used the arch will abutting the top guide rail
stop. Accordingly, selecting the bowden cable used selects whether
the arch is created in a upper-most position or a lower-most
position. These positions are separated by several inches.
[0015] Tractive forces applied to both bowden cables through a
single actuator. The ends of each bowden cable that are not
attached to the archable pressure surface are attached to a wheel
in the rotating actuator. Rotation of the wheel in one direction
applies traction to one bowden cable, and rotation of the wheel in
the opposite direction applies traction to the other bowden cable.
Thus, at one extreme rotation of the actuator wheel, the pressure
surface is fully flexed, fully drawn to the top end of the guide
rail and maintains an apex in the top position. Full rotation of
the actuator wheel in the opposite rotational direction forms the
pressure surface arch on the opposite end of the guide rail. Travel
from one actuator wheel extreme through a half-way point and to the
other actuator wheel extreme reduces tractive force on one cable,
moves through a half-way point where there is no tractive force on
either cable and then applies an opposite tractive force on the
opposite bowden cable. When the actuator wheel travels through the
half-way point where there is no traction on either cable, the
archable pressure surface is flat.
[0016] Further features and advantages of the present invention, as
well as the structure and operation of various embodiments of the
present invention, are described in detail below with reference to
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of the lumbar support of the
present invention viewed from the rear, in the flat position.
[0018] FIG. 2 is a side view of the lumbar support of the present
invention.
[0019] FIG. 3 is a perspective view of the lumbar support of the
present invention viewed from the front.
[0020] FIG. 4 is a front view of the lumbar support of the present
invention.
[0021] FIG. 5 is a rear view of the lumbar support of the present
invention.
[0022] FIGS. 6A, 6B and 6C are schematic cut-aways of the rotating
actuator of the present invention.
[0023] FIG. 7 is a cut-away top view of the rotating actuator of
the present invention.
[0024] FIG. 8 is a back view of an alternative embodiment of the
present invention.
[0025] FIG. 9 is a side view of an alternative embodiment of the
present invention.
[0026] FIG. 10 is a perspective view of an alternative embodiment
of the present invention, from the rear, in its flat position.
[0027] FIG. 11 is a perspective view of an alternative embodiment
of the present invention, from the rear, in its low arch
position.
[0028] FIG. 12 is a perspective view of an alternative embodiment
of the present invention, from the front, in its low arch
position.
[0029] FIG. 13 is a perspective view of an alternative embodiment
of the present invention, from the front, in its flat position.
[0030] FIG. 14 is a perspective view of an alternative embodiment
of the present invention, from the rear, in its high arch
position.
[0031] FIG. 15 is a perspective view of an alternative embodiment
of the present invention, from the front, in its high arch
position.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 is a rear perspective view of the lumbar support of
the present invention. A flexible, archable pressure surface, 10,
has a top end, 12, and a bottom end, 14, each of which are mounted
to slide on a pair of guide rails, 16. In the depicted alternative
embodiment, guide rails, 16, are a single wire fabricated in a
generally U-shaped fashion to provide two lengths of wire, 16, that
guide arching pressure surface, 10. The guide rails have top end
stops, 20, and bottom end stops, 22, which prevent the archable
pressure surface, 10, from sliding beyond the stops. The archable
pressure surface is metal or plastic. It is biased towards
remaining flat. This internal bias is weak enough to be overcome by
a traction cable such as a bowden cable.
[0033] When the archable pressure surface, 10, is flat, the
distance between the sliding ends, 12 and 14, of the archable
pressure surface, 10, is substantially equal to the distance
between the guide rail end stops, 20 and 22. However, when the
pressure surface is arched, the distance between the sliding ends,
12 and 14, of the pressure surface is shorter than the distance
between the guide rail end stops, 20 and 22. The present invention
takes advantage of this gap between an arched pressure surface, 10,
and the guide rail stops, 20 and 22, in order to move the arched
pressure surface, and it's apex, up and down.
[0034] The guide rails have a center mounting bracket, 24, which
does not move. The mounting bracket, 24, is substantially half way
between the guide rail end stops, 20 and 22. Alternative,
non-centered mounts may be used to the same effect. Two bowden
cables are used to apply the traction that draws the pressure
surface top, 12, and bottom ends, 14, towards one another.
[0035] A top bowden cable, 30, has it's sleeve, 32, anchored at the
pressure surface top end, 12, and it's axial sliding wire, 34,
anchored at the center bracket, 24. In the depicted alternative
embodiment, top bowden cable sleeve, 32, is attached to the
archable pressure surface top end, 12, via spring, 36. Spring, 36,
mediates tension between bowden cable sleeve, 32, and arching
pressure surface top end, 12, and helps the unit tolerate abusive
loads. A second, bottom bowden cable, 38, has it's sleeve, 40,
anchored to the bottom, 14, of the archable pressure surface, 10,
and it's sliding axial wire, 42, anchored to the central mounting
bracket, 24. Traction drawing the bowden cable wires into the
bowden cable sleeves on either of these bowden cables will shorten
the distance between the top and bottom ends, 12 and 14, of the
arching pressure surface, 10, bowing it outwards and creating an
arch.
[0036] If traction is applied to the top bowden cable, 30, the
bowden cable sleeve end, 44, draws the top, 12, of the archable
pressure surface downwards towards the central bracket, 24, via
spring, 36. This also draws the opposing bottom, 14, of the
archable pressure surface downwards, where it is stopped by the
bottom guide rail stop, 22. Continuing traction draws the pressure
surface top end, 12, closer to the stopped pressure surface bottom
end, 14, causing the arching pressure surface, 10, to flex
outwards. This low arch position is shown in FIGS. 11 and 12, which
also depict alternative bowden cable attachments.
[0037] Conversely, traction on the second, bottom bowden cable, 38,
draws the bottom, 14, of the archable pressure surface, 10, towards
the central bracket, 24, where the bottom bowden cable wire, 42, is
mounted. The top, 12, of the archable pressure surface, 10, is
stopped by the top guide rail stop, 20, and continuing pressure on
the bottom bowden cable, 38, pinches the archable pressure surface,
20, between the bottom bowden cable sleeve, 46, and the top guide
rail stop, 20, again flexing the archable pressure surface, 10.
This high arch position is shown in FIGS. 14 and 15, also depicting
alternative bowden cable mounting.
[0038] The dimensions of the arch created by these motions are the
same if either the top or bottom bowden cable are used to create
it. If the top bowden cable, 30, is used to create the arch, the
arch will be abutting the bottom guide rail stop, 22, and if the
bottom bowden cable, 38, is used the arch will be abutting the top
guide rail stop, 20. Accordingly, selecting which bowden cable is
tensioned selects whether the arch is created in the upper position
or the lower position. These positions may be separated by a range
from 20 to 80 millimeters; for example, 56 millimeters separate the
high and low apex in FIG. 2.
[0039] FIG. 2 is a side view of the variable apex lumbar support of
the present invention. Schematic lines, 100 and 102, illustrate the
position of the archable pressure surface, 10, when fully arched.
Line, 100, illustrates archable pressure surface arched in its top
arch configuration, forming an apex at 104. Line 102 indicates the
archable pressure surface, 10, lower arched configuration, forming
an apex at 106. In the depicted alternative embodiment, the high
arch apex, 104, is 56 millimeters higher than the low arch apex,
106. The travel between high and low apex positions is proportional
to the amount of space between the archable pressure surface, 10,
and guide rail end stops, 20 and 22. With the archable pressure
surface, 10, in its high arch position, 100, the bottom end, 14, of
archable pressure surface, 10, is nearly 56 millimeters from bottom
guide stop, 22. When the archable pressure surface, 10, is in its
low apex position, 102, the top end, 12, of the archable pressure
surface, 10, is somewhat shorter than 56 millimeters from top guide
rail end stop, 20.
[0040] Ergonomic studies have compared the lumbar anatomy of five
foot tall persons to six foot tall persons and revealed that the
lumbar vertebrae intended to be supported by a lumbar support do
not vary vertically more than approximately 50 millimeters.
Accordingly, the vertical travel of the apex of the lumbar support
in the depicted embodiment is closely correlated to the range of
varying lumbar support apex positions found to be most comfortable
by seat occupants within the most common range of height.
[0041] As is best seen in FIG. 2, the pressure surface sliding
ends, 12 and 14, are at an oblique angle to the plane of archable
pressure surface, 10, in the flat position depicted in FIG. 2. This
angle, between 90 and 180 degrees, is selected to maximize the
horizontal travel of the apex of the arch created by archable
pressure surface, 10, when traction is applied to it. Horizontal
apex travel from flat to fully arched varies from about 10 to 50
millimeters in various models of lumbar supports. The described
angled relationship of sliding ends, 12 and 14, to archable
pressure surface, 10, increases horizontal apex travel by as much
as 10 millimeters.
[0042] Of course equivalent alternatives include anchoring one or
both bowden cable sleeves to the central bracket, 24, and mounting
the corresponding one or both bowden cable wires to the end
portions, 12 and 14, of archable pressure surface, 10. FIGS. 8,
through 15 depict such a bowden cable sleeve and bowden cable wire
attachment configuration. FIGS. 8 and 9 depict an alternative
embodiment of the present invention using an alternative pressure
surface. FIGS. 10 through 15 show the first pressure surface with
the alternative bowden cable attachments. The bowden cable
attachment configuration is equally applicable to all alternative
embodiments. In FIGS. 8 through 15, first bowden cable, 130, and
second bowden cable, 138, are both oriented towards the top of the
lumbar support as they exit actuator housing, 150. First bowden
cable sleeve, 132, is anchored at 144 to a top mounting bracket,
112. This mounting may also be had at top portion, 12, of an
archable pressure surface, 10. Second bowden cable sleeve, 140, is
anchored at 146 to the central mounting bracket, 124. The second
bowden cable wire, 142, extends from the central bracket to the
lower mounting bracket, 114, where it is also anchored. Since the
bowden cable sleeve end and the bowden cable wire end act in unison
to draw together whatever elements of the device are anchored to
the sleeve end and wire end, the novel action of the present
invention may be achieved with either bowden cable anchored in
either configuration.
[0043] Further features of the lumbar support of the present
invention are indicated on FIG. 3. A rotating actuator, 50, engages
bowden cables, 30 and 38, in order to put traction on the wires
within them, as is more fully described below. The rotating action
of actuator, 50, may be achieved by a variety of equivalent
alternatives, such as hand wheels or levers. In the depicted
alternative embodiment, the rotating actuator, 50, is driven by an
electric motor, 52. The rotating actuator, 50, may be loose and
mounted on the seat into which the lumbar support is installed, or,
as in the depicted alternative embodiment, may be anchored to the
lumbar support unit by bracket, 54, which extends laterally from
its fixation to central bracket, 24. The unitized assembly of the
depicted alternative embodiment eases packaging, shipping and
installation of the lumbar support into a seat.
[0044] The archable pressure surface, 10, has a number of ribs or
fingers, 60, to distribute the supporting area of the archable
pressure surface. The guide wire, 16, has brackets, 62, on it for
mounting the lumbar support into a variety of seats. Brackets, 62,
may be used to mount the lumbar support on a flexible wire mat, a
rigid frame, support wires or rods, sinuous wires or rigid seat
frame brackets.
[0045] FIGS. 4 and 5 are front and rear views of the lumbar support
of the present invention.
[0046] As is best seen in the rear view, FIG. 5, the depicted
alternative embodiment has a central bracket for anchoring bowden
cable wires. It is considered to be within the scope of the
invention that the bowden cable wires (or bowden cable sleeve ends)
may be anchored elsewhere, provided that one of the bowden cable's
wire or sleeve end is in tractive communication with the upper
portion of the archable pressure surface, and the other bowden
cable wire end or sleeve end is anchored elsewhere on the lumbar
support, off of the archable pressure surface. Selectively arching
the pressure surface in a high apex position or a low apex position
is by selectively drawing the lower portion upward towards the high
guide rail stop or drawing the upper pressure surface portion down
towards the low guide rail stop. This is considered to be within
the scope of the present invention regardless of whether or not a
central bracket is used for anchoring a traction element.
[0047] The Actuator
[0048] Tractive force is applied to both bowden cables through a
single actuator. The ends of each bowden cable that are not
attached to the archable pressure surface are attached to a wheel,
70, in the rotating actuator, 50, depicted in detail in FIGS. 6 and
7. Rotation of the wheel in one direction applies traction to one
bowden cable, and rotation of the wheel in the opposite direction
applies traction to the other bowden cable. Thus, at one extreme
rotation of the actuator wheel, the pressure surface is fully
flexed, fully drawn to the top end of the guide rail and maintains
an apex in the top position. Full rotation of the actuator wheel in
the opposite rotational direction forms the pressure surface arch
on the opposite end of the guide rail. Travel from one actuator
wheel extreme through a half-way point and to the other actuator
wheel extreme reduces tractive force on one cable, moves through
the half-way point where there is no tractive force on either cable
and then applies an opposite tractive force on the opposite bowden
cable. When the actuator wheel travels through the half-way point
where there is no traction on either cable, the archable pressure
surface is flat.
[0049] As seen in FIG. 7, housing, 76, encloses a drive wheel, 72,
engaged to receive driving force from electric motor, 52.
Relatively large drive wheel, 72, is fixedly attached to co-axial
drive sprocket, 74. Drive wheel, 72, having a large radius relative
to drive sprocket, 74, gives it mechanical advantage, allowing a
smaller, more compact and less expensive motor, 52, to be used.
Housing, 76, encloses drive wheel, 72, drive sprocket, 74, and
actuating wheel, 70. Bowden cables, 30 and 38, enter housing, 76,
through anchors, 78 and 80. The bowden cable sleeves, 32 and 40,
are anchored at 78 and 80. The bowden cable wires, 34 and 42, enter
through sleeves 32 and 40, through anchors 78 and 80, to where they
engage with actuator wheel, 70. Wires, 34 and 42, are attached to
actuator wheel, 70, at eyelets, 82 and 84. Each bowden cable wire,
34 and 42, wraps around actuator wheel, 70, in an opposite
direction to reach their respective eyelets, 82 and 84. Actuator
wheel, 70, has teeth, 86, which engage with the teeth of drive
sprocket, 74. In the depicted alternative embodiment, drive
sprocket, 74, has 7 teeth and actuator wheel, 70, has 28 teeth. The
range of rotation for actuator wheel, 70, is 242 degrees. This
corresponds to a total cable travel of 80 millimeters.
[0050] Other tooth ratios, rotation angles and travel lengths are
within the scope of the invention. For example, a lever or
handwheel can achieve 40 millimeters of horizontal apex travel from
flat to fully arched with 120 degrees of rotation and 20
millimeters of cable travel. In this configuration, zero degrees
would correspond to a fully arched apex in the low position, 60
degrees from that position would be the flat intermediate position
and 120 degrees would correspond to a fully arched apex in the high
position. Forty millimeters of in and out travel are achieved by
centering the lever at the 60 degree position of the rotating
actuator wheel so that 20 millimeters of travel towards the zero
degree position achieves the low arch, while 20 millimeters of
cable travel towards the 120 degree position achieves the high
arch. Ratchet or overrunning clutch actuators, as are know in the
art, may also be used. Substantially the same degree of apex
horizontal travel can be achieved with substantially the same
amount of cable travel in a ratchet actuator with 7 millimeters of
travel per ratchet lever arm turn. Accordingly, three ratchets in
one direction will achieve the high apex, while 3 ratchets from
center in the opposite direction will achieve the low apex.
[0051] In operation, the full range of movement of the archable
pressure surface from low arch through a middle flat position to
high arch are controlled by the position of actuator wheel, 70, and
the traction it exerts on bowden cable wires, 34 and 42. In FIG.
6A, actuator wheel, 70, is at its position corresponding to the
archable pressure surface being fully arched in the low apex
position. Lower bowden cable wire, 42, has no tractive force being
exerted on it and is short relative to upper bowden cable wire, 34,
in the portion of that wire depicted in FIG. 6A. Engagement of
electric motor, 52, turns drive wheel, 72, which turns drive
sprocket, 74, which turns actuator wheel, 70, counterclockwise
towards and through the neutral position depicted in FIG. 6B. At
this position there is no tractive force being exerted on either
bowden cable wire and, accordingly, the archable pressure surface
is flat. Continuing engagement of motor, 52, drives actuator wheel,
70, further counterclockwise. As actuator wheel, 70, proceeds in
that direction, it begins to draw lower bowden cable wire, 42, out
of its anchored sleeve, 40. This exerts the tractive force
necessary to draw the archable pressure surface, 10, into its
restraining engagement with guide wire top stop, 20. As actuator
wheel, 70, continues to turn it exerts continuing tractive force on
lower bowden cable wire, 42, which force is transferred to the
archable pressure surface by drawing the end of bowden cable wire,
42, anchored to central bracket, 24, towards the bowden cable
sleeve end, 46, which is anchored to the archable pressure surface
lower end, 14, drawing it upwards. The upwards tractive force on
bottom end, 14, arches the pressure surface, 10, in the manner
described above. Continuing rotation of actuator wheel, 70, until
its limit depicted in FIG. 6C puts the archable pressure surface,
10, into its upper arching position with the apex fully
extended.
[0052] It is contemplated to be within the scope of the present
invention that a single bowden cable can be used, with a single
bowden cable wire. A first end of the wire is attached to the
central bracket, and the second end is also attached to the central
bracket, but from the other side. A centrally located crimp, pin,
rack and pinion, lever or other fixation anchors a central portion
of the single bowden cable wire to the actuator wheel for receiving
tractive force selectively to one or the other sections of the
single bowden cable wire for putting tension on the archable
pressure surface with either the first or second end of the single
bowden cable.
[0053] FIGS. 8 and 9 depict an alternative application of the
present invention. Archable pressure surfaces may be fabricated out
of metal or plastic into a ribbed assembly with engaging upper and
lower ends as depicted in FIGS. 1 through 5 and 10 through 15.
Archable pressure surfaces may also be fabricated of hinged flexing
rods that support lateral wires. FIG. 8 is a front view of such a
flexible wire mat type of arching lumbar support. Again there are
guide rails, 116. Again the guide rails have top stops, 120, and
lower stops, 122. In the depicted alternative embodiment, these are
quite simply fabricated by bending the wire at the appropriate
distance.
[0054] In the flexible wire mat alternative embodiment, the arching
pressure surface is comprised of two flexible rods, 110. These rods
support a plurality of lateral wires, 160.
[0055] The archable flexible rods, 110, are hingedly attached to an
upper sliding bracket, 112, and a lower sliding bracket, 114.
Brackets, 112 and 114, may be molded plastic or stamped metal. In
either case, they are mounted to slide on guide rails, 116.
Brackets, 112 and 114, also have a detent or hole, 113 and 115, for
receiving a hinged insertion of the ends of arching pressure rods,
110. When traction is applied to draw upper bracket, 112, and lower
bracket, 114, towards one another, the brackets, staying in the
plane defined by guide rails, 116, slide towards one another along
guide rails, 116. Simultaneously, the ends of arching pressure
rods, 110, pivot in apertures, 113 and 115, allowing flexible rods,
110, to bow or arch outwards towards a seat occupant. Such an arch
is depicted in side view, FIG. 9.
[0056] Guide rails, 116, support a non-moving central bracket, 124.
Upper bowden cable, 130, has its sleeve, 132 mounted to bracket,
112, at sleeve end, 144. Upper bowden cable, 130, has a wire, 134,
which extends out of sleeve, 132, to where its end is anchored to
central bracket, 124. Lower bowden cable, 138, has its sleeve, 140,
anchored to central bracket, 124, at sleeve end, 146. Lower bowden
cable wire, 142, extends out of sleeve end, 146, to where the end
of wire 142 is anchored to lower bracket, 114. The same actuator
principle is used as above. Sleeve anchors 78 and 80 may be fixed,
or pivot or slide. As described above, the actuator wheel and
housing may vary with varying configurations of the lumbar
support.
[0057] Motor, 152, drives actuator, 150, to selectively tension
either upper bowden cable, 130, or lower bowden cable, 138. If
upper bracket, 130, is selected, wire, 134, is drawn into sleeve,
132, moving upper bracket, 112, through traction at cable sleeve
end, 144, to move closer to central bracket, 24. This causes
pressure rods, 114, to bow outward creating an arch, since they
cannot move downwards as the lower bracket, 114, is stopped by
guide rail bottom stop, 122. Accordingly, an apex is formed in a
low apex position by tensioning the upper bowden cable, 130. A
upper apex is formed by a similar but converse operation of using
the actuator, 150, to put tractive force on lower bowden cable
wire, 142, through lower bowden cable sleeve, 140.
[0058] The cost savings of this invention are not only applicable
to simple apex height variance, but may also be incorporated with
more advanced features. More particularly, highly complex and
expensive massage units are available for the luxury seat market.
The present invention may be deployed to achieve a massaging effect
at a reduced cost in the following manner.
[0059] Programmed microchip control of moving ergonomic supports
may be integrated with the present invention. Programmed, cyclic
motion patterns may be maintained for pre-configured time periods
by integrating modules such as those disclosed in U.S. Pat. Nos.
5,816,653 and 6,007,151 with electric motor drive for the rotating
actuator of the present invention. Such cyclic motion control
microprocessor modules can take any electronically actuated lumbar
support through its full mechanical range of positions, either
continuously or intermittently, with or without pauses.
Accordingly, it is within the scope of the present invention to
incorporate such a cyclic motion pattern controlling microprocessor
module. The control module would be fixedly attached to the
actuator housing, electric motor assembly and wired to the electric
motor for control of it. Assuming a full range of motion of the
present invention is programmed into the module, the electric motor
would periodically rotate the actuator wheel, 70, through any
portion or all of its range. If the full range of motion is
programmed into the module, from a starting position, the module
would control the electric motor to rotate the actuator wheel
through the range including the low apex position, through a
rotation releasing tension on the upper bowden cable wire until the
archable pressure surface is flat, then continue rotating the
actuator wheel to apply tension to the lower bowden cable wire
until continued traction on it forms the upper apex position.
[0060] Continuing motion of the archable pressure surface after
rotation of the actuator wheel has proceeded to its mechanical
limit requires turning the actuator wheel back in the opposite
direction. This is achieved in a known manner by using, as
equivalent alternatives, either stall sensors or position sensors
combined with a memory of the position corresponding to the
mechanical limits of the lumbar support. The position sensor may be
placed at a variety of locations, for example, on the actuator
wheel, along the bowden cable wire, or elsewhere. When the position
pre-configured to correspond to the mechanical limit of the
archable pressure surface indicates that a mechanical limit has
been reached, the control module is pre-configured to reverse the
direction of rotation of the actuating wheel. Alternatively, a
stall sensor may be used. Appropriate stall sensors include without
limitation amperage meters. When the electric motor current spikes,
indicating that the motor has stalled due to a mechanical limit
being reached, the control module may respond to the current spike
by reversing the direction of the actuating wheel rotation.
[0061] Timers may be incorporated in the control module and
pre-configured so that pauses in the cycling motion of the lumbar
support may be maintained for any length of time. Hence movement of
the archable pressure surface may be continuous, may proceed in a
stepped fashion so that time intervals are so short and movement
magnitudes between pauses are so small that individual movements
and individual pauses are imperceptible to the seat occupant.
Alternatively, perceptible amounts of movement and pauses of time
may be pre-programmed. Finally, the time is pre-configured to cycle
for a given amount of time, for example ten minutes, and then stop.
Of course the seat occupant may stop the cycling motion by turning
off a switch in control of the control module, turning off the
automobile into which such a seat may be incorporated, or
repositioning a set position of the archable pressure surface with
a separate control.
[0062] It is further contemplated to be within the scope of the
present invention that the variable apex lumbar support may be
combined with other components in order to completely develop the
advantages of the present invention. For example, the variable apex
lumbar support of the present invention may be fitted with a
vibrator such as an eccentric weight or a pulse magnet vibrator.
When fitted with such a vibrator, such as at 100 on FIG. 11, the
lumbar support of the present invention may impart a massage effect
in any of its positions. Further, the vibrator can be combined with
the microprocessor described above so that a more complex massage
effect may be imparted to a seat occupant for a pre-configured
amount of time. Such combination would allow alternation between
the high and low apex on a continuing cycle while the entire unit
vibrates, thereby further promoting the comfort of the seat
occupant.
[0063] In view of the foregoing, it will be seen that the several
advantages of the invention are achieved and attained.
[0064] The embodiments were chosen and described in order to best
explain the principles of the invention and its practical
application to thereby enable others skilled in the art to best
utilize the invention and various embodiments and with various
modifications as are suited to the particular use contemplated.
[0065] As various modifications could be made in the constructions
and method herein described and illustrated without departing from
the scope of the invention, it is intended that all matter
contained in the foregoing description or 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.
* * * * *