U.S. patent application number 10/736717 was filed with the patent office on 2005-06-16 for energy management head restraint insert.
This patent application is currently assigned to Lear Corporation. Invention is credited to Locke, Gerald S., Veine, Eric.
Application Number | 20050127734 10/736717 |
Document ID | / |
Family ID | 34653938 |
Filed Date | 2005-06-16 |
United States Patent
Application |
20050127734 |
Kind Code |
A1 |
Veine, Eric ; et
al. |
June 16, 2005 |
Energy management head restraint insert
Abstract
An head restraint with an insert on seats in motor vehicles
whereby said head restraint controls occupant's head acceleration
and reduces neck loading in cases of impact. This head restraint
comprises a post of any shape inserted into a seatback, foam of a
desired thickness, an insert sized to cover a majority of the
surface area on the front face and top of said head restraint, and
a trim cover. Alternatively, the head restraint may be of integral
design without posts. The insert is meant to float within foam in
the head restraint and one can use clips or locating pins during
manufacturing to obtain desired floating effect.
Inventors: |
Veine, Eric; (Madison
Heights, MI) ; Locke, Gerald S.; (Lake Orion,
MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C. / LEAR CORPORATION
1000 TOWN CENTER
TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075-1238
US
|
Assignee: |
Lear Corporation
Southfield
MI
|
Family ID: |
34653938 |
Appl. No.: |
10/736717 |
Filed: |
December 16, 2003 |
Current U.S.
Class: |
297/391 |
Current CPC
Class: |
B60N 2/888 20180201 |
Class at
Publication: |
297/391 |
International
Class: |
A47C 001/10 |
Claims
1-4. (canceled)
5. A head restraint arrangement for a vehicle seat, the head
restraint arrangement comprising: a head restraint post associated
with the vehicle seat; a head restraint cushion disposed around the
head restraint post; and an insert panel disposed in the head
restraint cushion and spaced apart from the head restraint post;
wherein the insert panel is adapted to move toward the head
restraint post in response to force exerted by a head of an
occupant and distribute force to reduce deformation of the head
restraint cushion.
6. The head restraint arrangement of claim 5 wherein the insert
panel further comprises a plurality of apertures filled with
foam.
7. The head restraint arrangement of claim 5 further comprising a
trim cover disposed proximate an outer surface of the head
restraint cushion.
8. The head restraint arrangement of claim 7 wherein the insert
panel is wider than the head restraint post in a direction
extending substantially parallel to the outer surface.
9. The head restraint arrangement of claim 5 wherein the insert
panel further comprises a first section that extends generally
parallel to a front surface of the head restraint arrangement.
10. The head restraint arrangement of claim 9 wherein the insert
panel further comprises a second section disposed adjacent to the
first section and above the head restraint post.
11. The head restraint arrangement of the claim 10 wherein the
second section extends away from the head of the occupant.
12. The head restraint arrangement of claim 5 wherein the head
restraint arrangement is integral with the seatback.
13. The head restraint arrangement of claim 5 wherein the head
restraint cushion further comprises a front surface and a top
surface, and the insert panel further comprises a first section
having a first section surface area and a second section having a
second section surface area, wherein the first section surface area
is greater than a majority of the front surface and the second
section surface area is greater than a majority of the top
surface.
14. A vehicle seat for use with a vehicle, the vehicle seat
comprising: a seatback; a head restraint support attached to the
seatback; a head restraint cushion formed around the head restraint
support, the head restraint cushion having an outer surface; a trim
cover disposed proximate the outer surface; and a generally
L-shaped insert panel disposed in the head restraint cushion such
that the insert panel is spaced apart from the head restraint
support, the insert panel including a generally planar first
portion disposed between the trim cover and the head restraint
support and a second portion integrally formed with the first
portion and disposed above the head restraint support; wherein the
insert panel is adapted to move between an initial position and an
actuated position in which the insert panel is moved toward the
head restraint support upon application of rearward force by a head
of an occupant.
15. The vehicle seat of claim 14 wherein the insert panel reduces
penetration of the head into the head restraint cushion.
16. The head restraint arrangement of claim 14 wherein the insert
panel is made of plastic.
17. The head restraint arrangement of claim 14 wherein the insert
panel is made of metal.
18. A method of making a head restraint arrangement for a vehicle
seat, the head restraint arrangement including an insert panel, an
head restraint post, and a head restraint cushion, the method
comprising: positioning the insert panel and the head restraint
post in a cavity such that the insert panel is spaced apart from
the head restraint post; and providing a foam material that
encapsulates the insert panel and at least a portion of the head
restraint support to define the head restraint cushion; wherein the
foam material permits movement of the insert panel relative to the
head restraint post and inhibits the insert panel from contacting
the head restraint post.
19. The method of claim 18 wherein the cavity is defined by a trim
cover.
20. The method of claim 19 wherein the trim cover further comprises
an aperture for receiving a locating pin.
21. The method of claim 20 wherein the step of positioning the
insert panel further comprises providing a locating pin that
extends from a surface of the insert panel and positioning the
locating pin to effect positioning of the insert panel.
22. The method of claim 20 wherein the locating pin is disposed on
a side of the insert panel facing away from the head restraint
post.
23. The method of claim 20 further comprising the step of removing
the locating pin after the foam material is provided.
24. The method of claim 20 further comprising the step of removing
the locating pin from the insert panel after the head restraint
cushion is formed.
Description
FIELD OF INVENTION
[0001] This invention relates to head restraints in motor vehicles.
More specifically, it relates to a safer head restraint and
manufacturing thereof by utilizing a floating insert to increase
head restraint stiffness and energy management without necessarily
changing the foam or posts of traditional head restraints.
BACKGROUND OF INVENTION
[0002] Today, most, if not all, motor vehicles come with seats
equipped with head restraints. Head restraints provide not only
comfort for riders but also are there to protect an occupant's head
and neck in case of an accident.
[0003] Many current head restraints use U or M shaped posts with
foam covering the posts. These head restraints simply have the foam
interior molded around the posts. See U.S. Pat. No. 6,120,100 for
an example. A problem with this design is that the foam is often
times too soft and does not provide adequate structure within the
head restraint. In the event of a rear impact, the head may
penetrate too deeply between or above the post structure,
increasing the forces on the neck. A more uniform loading surface
is desired to control head displacement in all potential areas of
head contact.
[0004] Comfort requirements can work against safety recommendations
of using stiffer foam to reduce head movement during a crash. A
method of reducing head penetration without significantly changing
the comfort of the head restraint is greatly desired. It should
also be noted that the application of this type of insert to a seat
with an integrated head restraint (also known as a high-back seat)
serves a similar benefit. In this case, the posts are replaced by
some other seat back structure.
[0005] Regulatory actions are mandating that head contact surfaces
return to within a small distance of the initial position after
load-deflection tests are completed. Soft foam has a slow recovery
time. As a result, many head restraints do not meet some safety
standards imposed on motor vehicle manufacturers.
SUMMARY OF INVENTION
[0006] The object of this invention is to overcome the
above-mentioned problems with current head restraints. A floating
insert of a somewhat rigid material would help reduce neck injuries
and help meet safety regulations.
[0007] Accordingly, this head restraint comprises a post, foam, an
insert, and trim cover. Alternatively, the head restraint may be
integrated and supported by some other seat back structure. The
insert is placed so that the insert will cover a majority of the
surface area on the front face and top of the head restraint. The
insert may be held in place for manufacturing by any number of
existing or new methods. Foam is then applied over the insert and
post, if present. The insert may have holes designed to allow foam
to completely fill the area around it. A trim cover is typically
applied over the head restraint, but the requirement of a cover is
optional.
[0008] This invention solves the above-mentioned problems by using
an insert that possesses good elastic properties. This insert in
head restraints provides a more uniform stiffness and energy
management without having to change foam or posts in current head
restraints. It will also provide a more uniform loading surface for
an occupants head. Unlike many inserts that are rigidly attached to
the post or other seat back structure, this insert is allowed to
move relative to the structure under test or crash conditions. This
action controls the acceleration of the head to reduce the peak
magnitude while simultaneously minimizing the penetration. The
effect is to reduce forces and moments on the neck as well as to
reduce the head rotation relative to the torso.
[0009] For the foaming process, the insert may be held into
position relative to the post by clips over the post. These clips
are designed in a manner that provides little resistance to the
movement of the insert under head impact conditions. Alternatively,
when a post is not present, removable locating pins may be used in
the foaming process to position the insert.
[0010] Additionally, the elasticity of the insert would help head
restraints to meet the deflection criteria for backset retention
and height retention. The insert will assist the foam recovery so
that the foam will return to acceptable limits within a reasonable
time after the loading event.
DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a side cross-sectional view of the head
restraint.
[0012] FIG. 2 depicts the method of using locating pins to keep the
insert in place while the foam is being poured.
[0013] FIG. 3 depicts a rear view of the method of using clips on
the insert to keep the insert in place.
[0014] FIG. 4 depicts the action of an occupant's head on impact
and the way the insert assists with controlling head and neck
movement.
[0015] FIG. 5 is a top view of the occupant's head on impact and
the use of the insert to help control head and neck movement.
[0016] FIG. 6 is a view of the seat insert located in a high-back
seat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] With reference to FIG. 1, this invention comprises a post 4,
foam 6, an insert 8, and trim cover 14 creating head restraint 2.
This insert 8 that is the object of this invention will be sized to
fit any variety of head restraints. Generally, head restraints use
an M or U shaped post but the insert 8 can be designed to fit any
shaped post.
[0018] The insert 8 is molded into the foam 6 on the front side of
the post 4 at some nominal distance below the surface of the head
restraint 2. The insert 8 needs to be buried within the foam 6 so
that the head restraint 2 still is comfortable for occupants. This
insert 8 also needs to cover a majority of the front surface area
and top of the head restraint 2. The insert 8 could also be formed
to fit a variety of head restraint contour designs. Additionally,
the insert 8 can comprise of plastic, metal, or a composite
material. The versatility of the designs for this insert 8 allow it
to be used in most if not all head restraints.
[0019] The insert 8 is not meant to be rigidly attached to the post
4. The safety feature of this insert 8 works best when the insert 8
floats inside the foam 6. However, the insert 8 must be able to
stay in place while the foam 6 is molded over the post 4 and insert
8. In one embodiment of this invention, seen in FIG. 3, the insert
8 is fashioned with clips 10. These clips 10 hold the insert 8 in
place over the post 4. Then the foam 6 is poured over the insert 4
and post 6. These clips 10 are strong enough to hold the insert 8
in place but weak enough to break away when impacted by occupant's
head. By the clips 10 being able to break away, this still
maintains the object of the insert 8 that it floats in the foam.
The trim cover 14 envelopes the post 4, foam 6, and insert 8.
[0020] Another embodiment of this invention, seen in FIG. 2, is
that the insert 8 utilizes locating pins 12. The locating pins 12
would mate with holes in the insert 8 to locate the position of the
insert 8 over the post 4. The locating pins 12 would then hold the
insert 8 in place while the foam 6 is poured over the post 4 and
insert 8. Once the foam 6 is poured, then the locating pins 12
would be pulled out. The trim cover then envelopes the post 4, foam
6, and insert 8.
[0021] FIG. 4 and FIG. 5 show how the head restraint insert 8 aids
in controlling the motion of an occupants head and neck in cases or
rear impact. This controlled motion helps to reduce injury that is
common in rear impacts.
[0022] FIG. 6 depicts another embodiment of this invention. In a
high-back seat, there is not a separate head restraint. However,
this insert can still be used to protect and occupants head and
neck. The insert 8 is simply located in a position near the top of
the high back seat so that in cases or rear impact, the insert 8
will provide the same safety features as it would in a separate
head restraint.
[0023] The above presents a description of the best mode
contemplated for carrying out this invention. The claims should not
be read as limited to the described order or elements unless stated
to that effect. Therefore, all embodiments that come with the scope
and spirit of the following claims and equivalents thereto are
claimed as the invention.
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