Overmolded track for an integrated thigh-extension of a vehicle seat

• US 9,981,582 B2
• Filed: 04/06/2016
• Issued: 05/29/2018
• Est. Priority Date: 04/06/2016
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Line, Johnathan Andrew, Kondrad, Marcos Silva, Casey, Carol, Brinker, Rodney Charles
• Primary Examiner(s): Brindley, Timothy J
• Application Number:
  US15/091,803
• Publication Number:
  US 20170291520A1
• Time in Patent Office: 783 Days
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 45/14336 Coating a portion of the article, e.g. the edge of the article B29C45/14573 and B29C45/14598 take precedence
• CPC Class Codes: B29C 49/20 of articles having inserts or reinforcements ; Handling of inserts or reinforcements
• CPC Class Codes: B29C 65/70 by moulding using a particular moulding technique, see the relevant technique , e.g. by injection B29C45/14467
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2995/0087 Wear resistance
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B60N 2/02253 characterised by the transmission between the electric motor and the seat or seat parts
• CPC Class Codes: B60N 2/0284 Adjustable seat-cushion length B60N2/0224 takes precedence
• CPC Class Codes: B60N 2/62 Thigh-rests B60N2/914 takes precedence

Abstract

A thigh-extension for a vehicle seat includes a metallic thigh-extension plate, an extension track defined by a low-friction resin overmolded onto the thigh-extension plate and a thigh-extension slider having an integral groove slidably engaged with the extension track to define a plurality of thigh-extension positions.

Claims

1. A vehicle seat comprising:

a seat frame;

a first thigh-extension plate coupled to the seat frame, wherein the first thigh-extension plate is metallic and includes an overmold that includes a first pair of inner and outer extension tracks, wherein the overmold is overmolded onto a portion of the first thigh-extension plate; and

a first thigh-extension slider engaged with the first thigh-extension plate, wherein the first thigh-extension slider defines inner and outer grooves that slidably engage the inner and outer extension tracks, respectively, of the overmold of the first thigh-extension plate to define a plurality of first thigh-extension positions.

2. The vehicle seat of claim 1, further comprising:

a second thigh-extension plate coupled to the seat frame, wherein the second thigh-extension plate includes a second pair of inner and outer extension tracks overmolded onto a portion of the second thigh-extension plate; and

a second thigh-extension slider engaged with the second thigh-extension plate, wherein the second thigh-extension slider defines inner and outer grooves that slidably engage the second pair of inner and outer extension tracks, respectively of the second thigh-extension plate to define a plurality of second thigh-extension positions, wherein the first thigh-extension plate and first thigh-extension slider define a right thigh extender, and wherein the second thigh-extension plate and second thigh-extension slider define a left thigh extender.

3. The vehicle seat of claim 2, further comprising:

first and second motors engaged with the first and second thigh-extension sliders, respectively, wherein the first and second motors selectively and independently operate the first and second thigh-extension sliders between the pluralities of first and second thigh-extension positions, respectively.

4. The vehicle seat of claim 2, wherein the first and second pairs of inner and outer extension tracks include a low-friction resin, and wherein the first pair of inner and outer extension tracks are overmolded on inner and outer edges, respectively, of the first thigh-extension plate, and wherein the second pair of inner and outer extension tracks are overmolded on inner and outer edges, respectively, of the second thigh-extension plate.

5. The vehicle seat of claim 4, wherein the low-friction resin is acetyl.

6. The vehicle seat of claim 2, wherein the first and second thigh-extension sliders are made of glass-filled nylon.

7. The vehicle seat of claim 3, wherein the first and second motors are screw-drive motors.

8. The vehicle seat of claim 2, wherein the first and second thigh-extension plates are metallic plates that are fixedly connected to the seat frame.

9. The vehicle seat of claim 2, wherein the first and second thigh-extension sliders include respective first and second thigh cushions that operate with the first and second thigh-extension sliders to further define the respective pluralities of first and second thigh-extension positions.

10. A thigh-extension for a vehicle seat comprising:

a metallic thigh-extension plate;

an extension track defined by a low-friction resin overmolded onto the metallic thigh-extension plate, the low-friction resin forming inner and outer extension tracks; and

a thigh-extension slider that includes integral inner and outer grooves that slidably engage with the inner and outer extension tracks that are made of the low-friction resin that is overmolded onto the metallic thigh-extension plate.

11. The thigh-extension of claim 10, wherein the low-friction resin is acetyl.

12. The thigh-extension of claim 10, wherein the thigh-extension slider includes glass-filled nylon.

13. The thigh-extension of claim 12, wherein the thigh-extension slider includes 15 percent glass-filled nylon.

14. The thigh-extension of claim 10, wherein the thigh-extension plate is fixedly connected to a seat frame.

15. The thigh-extension of claim 10, further comprising:

a screw-drive motor coupled to the thigh-extension slider and the thigh-extension plate, wherein the motor selectively operates the thigh-extension slider between the plurality of thigh-extension positions relative to the thigh-extension plate.

16. A method of forming a thigh-extension for a vehicle seat, the method comprising steps of:

overmolding a low-friction resin onto a metallic thigh-extension plate to define inner and outer thigh-extension tracks;

sliding a nylon thigh-extension slider onto the inner and outer thigh-extension tracks, wherein the nylon thigh-extension slider includes inner and outer grooves that slidably engage the inner and outer extension tracks, respectively; and

attaching the metallic thigh-extension plate to a seat frame.

17. The method of claim 16, further comprising a step of:

attaching a motor to the metallic thigh-extension plate and the nylon thigh-extension slider, wherein the motor selectively operates the nylon thigh-extension slider between a plurality of thigh-extension positions relative to the metallic thigh-extension plate.

18. The method of claim 16, wherein the low-friction resin is acetyl, and wherein the nylon thigh-extension slider includes glass-filled nylon.

19. The method of claim 16, further comprising:

attaching an adjacent metallic thigh-extension plate to the seat frame, where the metallic thigh-extension plate and the adjacent metallic thigh-extension plate at least partially define left and right operable thigh-extensions.