Chairs and seats – Movable back – Tiltable
Reexamination Certificate
2000-02-14
2001-11-27
Brown, Peter R. (Department: 3636)
Chairs and seats
Movable back
Tiltable
C297S362110, C074S089140, C074S60600R
Reexamination Certificate
active
06322146
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a seat recliner and, in particular, to a powered seat-recliner system having a lightweight plastic transmission housing with high load-carrying capacity.
In a conventional power linear seat-recliner system, a central motor drives a single or pair of actuator cables that, in turn, plug into gear nut(s) that engage threaded shaft(s) in transmission housings on opposite lateral sides of the seat. The threaded shafts, which reciprocate linearly, are secured to a pivoting mechanism that provides seat back reclining adjustment proportional to the linear motion of the threaded shaft.
Typically, transmission housings are cast aluminum, which is relatively expensive and suffers from varying dimensions as the die-cast mold wears. That is, as a mold is repeatedly used to cast aluminum transmission housings, wear on the mold through repeated use eventually skews the dimensions of the die cast parts. Because the transmission housing is a precision part, such wear causes the part to fail to meet required tolerances, often requiring that tolerances be met by adding thrust bearings of varying widths. Further, aluminum is a relatively expensive material from which to make transmission housings.
Notwithstanding the problems associated with mold wear, cast aluminum recliner housings have achieved widespread acceptance due, at least in part, to the ability of the aluminum material and cast housing to withstand the significant forces present during use. The magnitude of these forces, in conjunction with the need to insure that the transmission housing is robust in construction and performance, have dissuaded acceptance of transmission housings formed of alternative materials. However, a need remains for a less expensive and lightweight transmission housing that meets or exceeds the operational capabilities of accepted cast aluminum housings.
SUMMARY OF THE INVENTION
In view of the above, a first object of the present invention is to provide a transmission housing having a mounting assembly and gear housing that is lightweight yet capable of withstanding the forces to which linear recliner assemblies are subjected.
Another object of the present invention is to provide a gear housing for a linear recliner assembly that is fabricated of a lightweight polymeric material and configured to accommodate and operatively interconnect a recliner drive mechanism and a driven mechanism such as the recliner rod.
Yet another object of the present invention is to provide a transmission housing, including a mounting assembly and gear housing, that occupies a relatively small package area and is durable and reliable in operation.
Accordingly, the illustrated embodiment of the present invention includes a linear recliner assembly having a transmission housing that includes a U-shaped outer plate overlapping a U-shaped inner plate with a gear retainer housing therebetween. The gear retainer housing is fabricated from a plastic material, preferably nylon, and provides a lightweight, high-load carrying capacity housing in a small package and at a relatively low cost. The assembled transmission housing receives a transmission rod having a worm gear for linearly driving a threaded recliner rod. A user-actuable motor rotates the transmission rod within the transmission housing, which thereby imparts linear movement to the recliner rod through the transmission housing for providing reclining adjustment of a seat back relative to a seat cushion.
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Brown Peter R.
Fisher Dynamics Corporation
Harness & Dickey & Pierce P.L.C.
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