CN110356301B

CN110356301B - Adjustable support system

Info

Publication number: CN110356301B
Application number: CN201910495681.6A
Authority: CN
Inventors: 罗伯特·J·麦克米伦; 霍里亚·布兰迪尔; 保罗·廷德尔
Original assignee: Leggett and Platt Canada Co
Current assignee: Leggett and Platt Canada Co
Priority date: 2014-01-15
Filing date: 2015-01-14
Publication date: 2022-10-18
Anticipated expiration: 2035-01-14
Also published as: JP2020128210A; JP7061154B2; CN110356301A; CN105916407B; JP2017502771A; KR102327474B1; KR20160107183A; JP6730924B2; WO2015106338A1; CN105916407A

Abstract

The present invention provides an adjustable support system for a seat having a frame, comprising: a support movable relative to the frame from a first position to a second position; an actuator comprising a motor; a component operably coupled to the support and the actuator and movable by the motor, configured to be removably coupled to the support at different locations; a flexible cable having a first end coupled to the member for movement along a length of the member and a second end coupled to the frame such that movement of the member by the motor causes the flexible cable to move the support relative to the frame between the first and second positions.

Description

Adjustable support system

The application is a divisional application of the Chinese patent application with the application number of 201580004720.8, namely the lumbar support system, and the application date of 2015, 1 month and 14 days.

Technical Field

The present invention relates to a lumbar support system for use in a seat, in particular for use in a vehicle seat.

Background

Many lumbar support systems use electromechanical actuators to move a load via a Bowden cable. However, the use of Bowden cables often results in poor overall system efficiency, and such systems typically require multiple components to include a large heavy motor for actuation. In addition, these systems tend to emit noise during operation.

Disclosure of Invention

In one embodiment of a lumbar support system for a seat back, the system includes a fixed frame and a lumbar support coupled to the fixed frame, the lumbar support being movable from a first position to a second position. The motor is coupled to the lumbar support. A threaded member is operably engaged with the motor such that the motor rotates the threaded member about an axis. The first travel member is engaged with the threaded member and the second travel member is engaged with the threaded member. Rotation of the threaded member translates the first and second travel members in opposite axial directions along the threaded member. A spacer is located between the first and second travelling members. The spacer is configured to slide over the threaded member. A first flexible cable has a first end coupled to the first travel member for movement therewith, a second end coupled to the fixed frame, and an intermediate portion operatively associated with the lumbar support. A second flexible cable has a first end coupled to the second travel member for movement therewith, a second end coupled to the fixed frame, and an intermediate portion operatively associated with the lumbar support. In response to translation of the first and second travel members, the intermediate portion of the first flexible cable and the intermediate portion of the second flexible cable operate to move the lumbar support from the first position to the second position.

In one embodiment of a support system for a seat back, the system includes a fixed frame and a support. The support is in the form of a profile pad adapted to be mounted on the fixed frame. The contour pad includes a laterally positioned outer wire and a plurality of transverse wires. A first flexible cable is operatively coupled to the frame and has a first end, a second end, and a cable body. A second flexible cable is operatively coupled to the frame and has a first end, a second end, and a cable body. An actuator is configured to move the first and second flexible cables relative to the support. Upon actuation of the actuator, contact between the support and the cable body of at least one of the first and second flexible cables moves the support from a first position to a second position. The actuator is coupled only to the laterally positioned outer wire of the support.

In one embodiment of a lumbar support system for a seat back having a fixed frame, the system includes a lumbar support coupled to the fixed frame and a motor for moving the lumbar support, the lumbar support being movable from a first position to a second position. The threaded member is operatively associated with a motor such that the motor rotates the threaded member about an axis. The travel member is operatively associated with the threaded member such that rotation of the threaded member translates the travel member along the threaded member. The system further includes a flexible cable having a first end and a second end. The first end is coupled to the travel member for movement therewith and the second end is coupled to the fixed frame such that translation of the travel member in response to rotation of the threaded member moves the lumbar support element from the first position to the second position.

In one embodiment of an adjustable support system for a seat having a fixed frame, the adjustable support system includes a support that is movable from a first position to a second position relative to the frame. An actuator is coupled only to the support and is configured to move the support between the first position and the second position. A member is operatively associated with and movable by the actuator and has a length. The flexible cable has a first end and a second end. The first end is coupled to the member to travel along the length of the member and the second end is coupled to the fixed frame such that movement of the member by the actuator causes the flexible cable to move the support between the first position and the second position.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

Drawings

FIG. 1 is a perspective view of a vehicle seat including a lumbar support system.

Fig. 2 is a perspective view of the lumbar support system of fig. 1.

Fig. 3 is an exploded view of the lumbar support system of fig. 1.

Fig. 3A is an exploded view of the drive assembly of the lumbar support system of fig. 1.

FIG. 4 is a cross-sectional view of the lumbar support system in a retracted position along line 4-4 of FIG. 1.

FIG. 5 is a cross-sectional view of the lumbar support system in the extended position along line 4-4 of FIG. 1.

FIG. 6 is a perspective view of a vehicle seat including another lumbar support system.

Fig. 7 is a perspective view of the lumbar support system of fig. 6.

Fig. 8 is an exploded view of the lumbar support mechanism of the lumbar support system of fig. 6.

FIG. 9 is a cross-sectional view of the lumbar support system in a retracted position along line 9-9 of FIG. 6.

FIG. 10 is a cross-sectional view of the lumbar support system in the extended position along line 9-9 of FIG. 6.

Fig. 11 is a side view of the lumbar support system of fig. 6 with one lumbar support mechanism extended and the other lumbar support mechanism retracted.

FIG. 12 is a side view of the lumbar support system of FIG. 6 with one lumbar support mechanism retracted and the other lumbar support mechanism extended.

Figure 13 is a perspective view of another lumbar support system having a single lumbar support mechanism.

FIG. 14 is a partial perspective view of a vehicle seat including another lumbar support system.

Figure 15 is a perspective view of the lumbar support system of figure 14.

Fig. 16 is an exploded view of the lumbar support mechanism of the lumbar support system of fig. 14.

Fig. 17 is a partial front view of the lumbar support system of fig. 14.

FIG. 18 is a partial front view of the lumbar support system of FIG. 14 in a first position.

Fig. 19 is a partial side view of the lumbar support system of fig. 14 in a first position.

FIG. 20 is a partial front view of the lumbar support system of FIG. 14 in a second position.

Fig. 21 is a partial side view of the lumbar support system of fig. 14 in a second position.

FIG. 22 is a perspective view of another lumbar support system for a vehicle seat.

Fig. 23 is an exploded view of the lumbar support system of fig. 22.

FIG. 24 is a perspective view of the lumbar support system of FIG. 22 in an extended position.

Fig. 25 is a side view of the lumbar support system of fig. 22 in a retracted position.

Fig. 26 is a side view of the lumbar support system of fig. 22 in an extended position.

FIG. 27 is a perspective view of another lumbar support system for a vehicle seat.

Fig. 28 is an exploded view of the lumbar support system of fig. 27.

Figure 29 is a perspective view of the lumbar support system of figure 27 in an extended and lowered position.

Figure 30 is a perspective view of the lumbar support system of figure 27 in retracted and raised positions.

Figure 31 is a perspective view of the lumbar support system of figure 27 in an extended and raised position.

Figure 32 is an exploded view of another lumbar support system.

Fig. 33 is a rear perspective view of the lumbar support system of fig. 32.

FIG. 34 is a partial front perspective view of the lumbar support system of FIG. 32.

Fig. 35-37 are perspective views of three additional orientations of the lumbar support system of fig. 32.

Figure 38 is a rear perspective view of another lumbar support system.

FIG. 39 is a partial front perspective view of the lumbar support system of FIG. 38.

Fig. 40-42 are perspective views of three additional orientations of the lumbar support system of fig. 38.

Detailed Description

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. And as used in this application, the terms "upper," "lower," "top," "bottom," "front," "back," and other directional terms are not intended to require any particular orientation, but rather are used for descriptive purposes only.

Fig. 1 shows a seat 10, and for purposes of the following description, the seat 10 may be any vehicle seat within a passenger compartment of a vehicle, although the seat 10 is not necessarily limited to vehicle applications. The seat 10 generally includes a seat bottom 14 (shown in phantom) and a seat back 18 for horizontal and vertical support, respectively, of a seat occupant. The seat back 18 is able to fold relative to the seat frame at pivot 22. The frame 26, which is covered by an overlying cushion 30 (shown in phantom), provides structural integrity to the backrest 18, and the frame 26 includes a pair of

vertical support members

34, 38. The lumbar support system 100 extends between the

vertical support members

34, 38, and the lumbar support system 100 is coupled to the

vertical support members

34, 38 to allow for adjustable lumbar support for a seated occupant.

As shown in fig. 1, the lumbar support system 100 includes a lumbar support element or basket (basket) 110 centrally located between the

vertical support members

34, 38. The basket 110 presents a generally flat front face 114 adjacent the seat occupant, the front face 114 serving as a pressure surface against the lumbar region of the occupant. Additional cushions, pads, or other materials not shown are positioned on and within seat back 18 and between front face 114 and the seat occupant for added comfort.

Fig. 2 and 3 illustrate the lumbar support system 100 referenced with respect to the proximal end 120 (adjacent to the drive assembly 230) and the distal end 124. The upper and

lower portions

130, 134 of the basket 110 are formed to include a plurality of apertures 138 separated by strengthening ribs 142, the strengthening ribs 142 generally being connected to one another by a border 146 on a rear face 150 of the basket 110. The basket 110 includes a mounting surface 158 at a central portion 154 between the upper and

lower portions

130, 134. The mounting face 158 supports two opposing sets of guides 162, each set including an upper rail 166 and a lower rail 170, the upper and

lower rails

166, 170 extending laterally along the central portion 154 and converging toward the proximal and

distal ends

120, 124, respectively, of the basket 110 to form a cable channel 180, the purpose of the cable channel 180 being described below.

A pair of mounting pins 184 project rearwardly from the mounting face 158 for receipt within mounting holes 188 of the rigid spindle guide 192. The spindle rail 192 includes a set of upper and lower tabs 196, not shown, each having a centrally located aperture 200. When positioned adjacent the mounting face 158, the tabs 196 engage opposing hooks 204, the hooks 204, along with the mounting pins 184, align and secure the spindle guide 192 to the basket 110. Additional positioning and alignment is provided by the cooperation of the projections 208 on either side of the upper and lower tabs 196 with the slots 212 in the mounting surface (see also fig. 1). Structural integrity is maintained by contact between the inside surface of the spindle guide 192 and the block 216.

Referring to fig. 2, 3 and 3A, the drive assembly or actuator 230 includes: a motor 234; a motor shaft having a pinion 238; a housing 242; a worm gear 246; a cap 250 and a drive shaft 254. The motor 234 secured to the housing 242 with fasteners 256 is preferably a dc reversible motor, but can be any type of reversible motor suitable for the application and can be further sized and powered as necessary. The worm gear 246, which is operably engaged with the motor shaft pinion gear 238, allows for orthogonal changes in the direction of power applied to the drive shaft 254 and an increase in output torque from the motor 234. The gear 246 is contained within the housing 242, and the housing 242 also couples the motor 234 to the remaining drive assembly components. The splined drive shaft 254 cooperates with the worm gear 246 to rotate together and transmit power during operation. A cap 250 attached to the housing 242 provides additional protection for the worm gear 246 and drive shaft 254, and the cap 250 secures the motor 234 to the spindle rail 192.

A threaded member or spindle 260 is coupled to the drive shaft 254 and spans a substantial portion of the spindle guide 192. The main shaft 260 has proximal and distal threaded ends 264, 268. As shown, the proximal thread is a right-hand thread and the distal thread is a left-hand thread, but in alternative embodiments the chirality can be reversed. The proximal threaded end 264 is rotationally fixed to and received within an opening 272 defined in an end of the drive shaft 254 such that upon actuation of the motor 234, the main shaft 260 rotates with the drive shaft 254. A travel member or block (i.e., a proximal block 280 and a distal block 284) is positioned about each threaded

end

264, 268 of the main shaft 260. Each

slider

280, 284 has: an internally threaded body for engagement with the spindle 260; and

opposed grooves

290, 292, 294, 296 that mate with

opposed edges

300, 304 formed as part of the spindle guide 192. As the spindle rotates, the opposing threaded spindle ends 264, 268, in conjunction with the groove/rim interface of the slide blocks 280, 284 with the spindle guide 192, cause opposing translational movement of the slide blocks 280, 284 along the spindle 260. A bumper 308 positioned adjacent the drive shaft 254 provides a limit to one end of travel of the proximal slider 280. The second bumper 312 adjacent the centrally located stop 316 establishes a second travel limit and defines a range of movement of the proximal slider 280.

Proximal and distal

flexible cables

320, 324 are coupled to the proximal slider 280 and distal slider 284, respectively. Each

cable

320, 324 includes a first end 330, a second end 334, and a cable body 338. The first end 330 has a connector 344 that fits within the body of each

slider

280, 284 for movement therewith. The cable body 338 of each

cable

320, 324 extends from the first end 330, and the cable body 338 defines an intermediate segment 350, a portion of the intermediate segment 350 being located substantially within each respective channel 180. The intermediate segment 350 terminates at a second end 334 that is coupled to a roll end fitting 354 (e.g., the cable 324) or alternatively to a hook fitting 356 (e.g., the cable 320). The roll end fitting 354 is adapted to engage a first end 358 of a spring 362, such as a torsion spring. Although shown as being associated with the distal end 124, the spring 362 is operable with one or both of the respective second ends 334 of the distal and

proximal pull cables

320, 324. The spring 362 includes a second end 366, the second end 366 being configured to be attached to the hook end 370 of the hinge 374 and to allow for a limited amount of deflection of the lumbar support system 100 both when an occupant is first seated and during operation to enhance occupant comfort. The hook fitting 356 of the pull cable 320 wraps around a portion of the hook end 370 of the opposing hinge 374.

The hinge 374 is formed as a "living" hinge that abuts the basket 110 at both the upper and

lower portions

130, 134 on a side opposite the hook end 370. As shown, the hinge 374 includes first, second, and third pivot points 380, 384, 388, although fewer or more than three pivot points are within the scope. As shown in fig. 2, 4 and 5, the pivot points 380, 384, 388 are positioned to prevent interference with the motor 234 during the course of travel of the basket 110. The hinge 374 and the basket 110 are preferably formed as a single piece. Alternatively, the hinge 374 can be a separate piece secured to the basket 110 in a manner known to those skilled in the art. The hook end 370 of the hinge 374 is formed to fit over a coupling element in the form of an attachment wire 390 that is secured to the respective

vertical support member

34, 38 of the frame 26 (see fig. 1).

In operation, the seat occupant actuates the electrical actuator 230 using an electrically actuated switch preferably located adjacent the seat back 18 or the seat bottom 14. Referring to fig. 4 and 5, when the actuator 230 is activated, the lumbar support system can be in any position between a fully retracted position (fig. 4) and a fully extended position (fig. 5). When the motor 234 is energized, engagement of the worm gear 246 rotates the drive shaft 254, thereby simultaneously rotating the main shaft 260. If the lumbar support system 100 is activated to retract the basket 110, the spindle 260 rotates in a first direction. If the lumbar support system 100 is activated to extend the basket 110, the spindle 260 rotates in a second, opposite direction. Activation in either direction is user selectable using an electrically actuated switch. Due to the interaction of the

grooves

290, 292, 294, 296 of the

sliders

280, 284 with the

edges

300, 304 of the spindle guide 192, rotation of the spindle 260 translates the

sliders

280, 284, with one of the

sliders

280, 284 traveling in the proximal direction (120) and the other of the

sliders

280, 284 traveling in the distal direction (124).

If the occupant desires to extend the basket 110 to provide more lumbar support, clockwise rotation of the spindle 260 (as viewed from the distal direction 124) causes the proximal slider 280 to travel distally along the spindle 260 and the distal slider 284 to travel proximally along the spindle 260, i.e., the

sliders

280, 284 and their

respective attachment cables

320, 324 approach one another. As the

slides

280, 284 converge, a portion of the middle segment 350 of each cable slides within their respective channels 180, contacting the basket 110. This contact creates a force that guides the basket forward against the basket 110, as shown by arrow 392 in fig. 4. When the proximal slider 280 contacts the bumper 312, the motor 234 stops, which stops the rotation of the main shaft 260. Other methods of de-energizing the motor 234 at some point of travel known to those skilled in the art can also be used with the lumbar support system 100.

Hinges 374 anchored to the attachment wires 390 at the hook ends 370 facilitate movement of the basket 110 through flexure to provide smooth motion throughout the range of travel. As shown in fig. 5, the pivot points 380, 384, 388 allow the hinge 374 to fall around the motor 234 when fully extended. The attachment wires 390, each secured to a respective

vertical support

30, 34 of the frame 26, rotate as necessary with the movement of the lumbar support system 100.

If the occupant desires the basket 110 to be retracted to reduce the amount of lumbar support, the counterclockwise rotation of the spindle 260 causes the proximal slider 280 to travel proximally along the spindle 260 and the distal slider 284 to travel distally along the spindle 260, i.e., the

sliders

280, 284 and their

respective attachment cables

320, 324 are disengaged. As the

slides

280, 284 move farther apart, the pressure against the basket 110 from the middle segment 350 of the cable is relieved and the basket 110 retracts rearward in response as shown by arrow 394 in fig. 5. When the slider 280 contacts the bumper 308, the motor 234 stops as previously described.

During travel of the basket 110, from retracted to extended and from extended to retracted, the

cables

320, 324 remain disposed in substantially the same plane, and the angle α (see fig. 4) between the first end 330 and the second end 334 of each

cable

320, 324 remains obtuse.

Fig. 6 shows an alternative version of a lumbar support system 400 for a seat 410, the general features of which have been previously described. The seat 410 includes a seat bottom 414 (shown in phantom), a foldable seat back 418, and a frame 426 having

vertical support members

434, 438. The lumbar support element in the form of a contoured or deflection pad 440 includes laterally outer wires 444, a central wire 448, and a plurality of transverse wires 452 extending between the laterally outer wires 444. The frame 426 can further include a pair of receivers 456, the pair of receivers 456 for receiving a support of a headrest (not shown). As shown, the lumbar support system 400 includes a pair of independently adjustable

lumbar support mechanisms

500, 502.

Fig. 7 illustrates the lumbar support system 400 and fig. 8 details the components of the proximal adjustable lumbar support mechanism 500 referenced with respect to the proximal end 520 and the distal end 524.

The drive assembly or actuator 530 is substantially as shown in fig. 3A, and includes, as previously described with respect to the system of fig. 1: an interacting motor 534; a motor shaft with a pinion 538; a housing 542; a worm gear 546; a cap 550 and a drive shaft 554. A threaded member or spindle 560 is coupled to the drive shaft 554 and spans a substantial portion of the spindle rail 562. The main shaft 560 has a right-hand proximal thread and a left-hand distal thread. A proximal threaded end 564 is rotationally fixed to and received within an opening 572 defined by an end of the drive shaft 554, and upon actuation of the motor 534, the proximal threaded end 564 rotates with the drive shaft 554. A slider (i.e., a proximal slider 580 and a distal slider 584), each having an internally threaded body for engaging with the main shaft 560, is positioned about each threaded

end

564, 568 of the main shaft 560, respectively. The opposing

grooves

590, 592, 594, 596 mate with opposing

edges

600, 604 formed as part of the spindle guide 562 to cause opposing translational movement of the

sliders

580, 584 during operation. The bumper 608 located adjacent to the drive shaft 554 provides a first limit of travel of the proximal slider 580 and the second bumper 612 adjacent to the centrally located stop 616 provides a second limit of travel, these limits defining the range of movement of the proximal slider 580.

The proximal and

distal pull cables

620, 624 are coupled to the proximal slider 580 and the distal slider 584, respectively. Each

cable

620, 624 includes a first end 630, a second end 634, and a cable body 638. The first end 630 of each

cable

620, 624 includes a connector 644 coupled to the body of the

respective slider

580, 584 for movement therewith. The cable body of each

cable

620, 624 extends from the first end 630, and the cable body defines an intermediate section 650. As shown in fig. 8, the middle section 650 of the distal cable 624 of the proximal lumbar support mechanism 500 is longer than the middle section 650 of the proximal cable 620 of the same lumbar support mechanism. This longer intermediate section 650 of cable 624 is located within a rigid sleeve 652, which rigid sleeve 652 has an inner diameter larger than the diameter of cable 624 to allow free movement of cable 624 within rigid sleeve 652. A portion of the middle segment 650 of each of the proximal and

distal pull cables

620, 624 passes through and is contained by the clip 660, the clip 660 coupling the proximal and

distal pull cables

620, 624 and thereby the lumbar support mechanism 500 to the flexmat 440 through the outer wire 444. Each intermediate segment 650 terminates at a second end 634, the second end 634 being coupled to a hook fitting 668, the hook fitting 668 itself being secured to a respective

vertical support member

434, 438 of the frame 426. Referring to fig. 7, the distal lumbar support mechanism 502 is a mirror image of the proximal lumbar support mechanism 500.

The seat occupant can optionally choose to actuate either the proximal lumbar support mechanism 500 or the distal lumbar support mechanism 502 in the same manner. Alternatively, the seat occupant may be able to actuate both the proximal and

distal mechanisms

500, 502 with the same switch. The following operational description will focus on the support mechanism 500, but can be applied to the support mechanism 502 as well.

Using an electrically actuated switch preferably located adjacent the seat back 418 or seat bottom 414, the seat occupant activates the actuator 530 for the proximal lumbar support mechanism 500. Referring to fig. 9 and 10, when the actuator 530 is activated, the mechanism 500 can be in any position between a fully retracted position (fig. 9) and a fully extended position (fig. 10). Upon energizing the motor 534, engagement of the worm gear 546 causes the drive shaft 554 to rotate, thereby simultaneously turning the spindle 560. If the lumbar support mechanism 500 is activated to retract, i.e., provide less support, the spindle 560 rotates in a first direction. If the lumbar support mechanism 500 is activated to extend, i.e., provide more support, the main shaft 560 rotates in the opposite direction. Activation in either direction is user selectable using an electrically actuated switch. As with the embodiment of fig. 1, rotation of the spindle 560 translates the

sliders

580, 584, the

grooves

590, 592, 594, 596 of the

sliders

580, 584 interacting with the

edges

600, 604 of the spindle guide 562, such that one

slider

580, 584 travels in the proximal direction (520) and the

other slider

880, 884 travels in the distal direction (824).

Referring to fig. 17, the lumbar mechanism 800 is shown in an intermediate position between the first position and the second position. To move the lumbar support mechanism 800 to the first position of fig. 18 and 19, the seat occupant activates the mechanism to rotate the main shaft 860 clockwise (as viewed from the distal direction 824), which causes the proximal slider 880 to travel distally along the main shaft 860 and the distal slider 884 to travel proximally along the main shaft 860, i.e., the

sliders

880, 884 approach each other. As the

sliders

880, 884 converge with the respective connectors 944, the second intermediate segments 951 of the

cables

920, 924 are tensioned about the lateral outer wires 744 at the respective clips 960 in a manner similar to that described in fig. 6 et al. The portion of the deflection pad 740 spanned by the mechanism 800 in the upper waist region is thus forced forward as shown in figure 19. At the same time, the first intermediate segment 950 of the

cables

920, 924 slackens, resulting in greater support for the seat occupant in the upper lumbar region than in the lower lumbar region. When the proximal slider 880 contacts the bumper 912, the motor 834 is stopped, which stops the rotation of the main shaft 860.

To move the lumbar support mechanism 800 to the second position of fig. 20 and 21, the seat occupant activates the mechanism to rotate the main shaft 860 counterclockwise (as viewed from the distal direction 824), which causes the proximal slider 880 to travel proximally along the main shaft 860 and the distal slider 884 to travel distally along the main shaft 860, i.e., the

sliders

880, 884 separate. As the

slides

880, 884 are offset from the respective connectors 944, the first intermediate segments 950 of the

cables

920, 924 are tensioned about the lateral outer wires 744 at the respective clips 960 in a manner similar to that described in fig. 6 et al. The portion of the deflection pad 740 spanned by the mechanism 800 in the lower waist region is thus forced forward as shown in fig. 21. At the same time, the second intermediate segment 951 of the

cables

920, 924 slackens, thereby causing the seat occupant to be supported more in the lower lumbar region than in the upper lumbar region. When the proximal slider 880 contacts the bumper 908, the motor 834 is stopped.

As in the figure19 and 21, a vertical distance D separating the upper waist region from the lower waist region ₂ Is about 70mm but can have a higher or lower amplitude for a particular application. In some configurations, the lumbar support mechanism 800 is configured to provide support only at the limits of the range shown in fig. 19 and 21. In other configurations, the mechanism 800 is operable and provides support at any position within the range shown in fig. 19 and 21.

Fig. 22 shows another lumbar support system 1000 for a vehicle seat, the general features of which have been previously described. System 1000 includes a self-contained frame portion 1010, which frame portion 1010 can be integrated with a seat, and frame portion 1010 has

vertical support members

1020, 1024 for mounting flexible lumbar support elements in the form of baskets 1040. The basket 1040 includes a resilient connector 1044 near the top edge 1048 to facilitate travel of a portion of the basket 1040 along the

vertical support members

1020, 1024. As shown, the lumbar support system 1000 includes an adjustable lumbar support mechanism 1100.

Referring also to fig. 23, a drive assembly or actuator 1130 similar to that shown in fig. 3A includes a motor 1134, a housing 1142, a bracket 1144, and a worm gear arrangement (not shown) operable for rotating a threaded member or spindle 1150 orthogonally to the motor drive shaft (not shown), i.e., the spindle 1150 is oriented in a generally vertical direction relative to the seat. A traveling member or slide 1160 having an internally threaded body for engagement with the spindle 1150 is positioned about the threads of the spindle 1150.

The rigid support wire 1170 includes: a pair of

hooks

1174, 1176 for engagement with the lower base member 1052 of the basket 1040; and a rail portion having first and second connected

parallel rails

1180, 1184. The support wire 1170 further forms a loop 1190 between the rail 1184 and the hook 1176. An end member 1200 having a semicircular channel 1204 sized to receive the

rails

1180, 1184 includes a guide 1210 extending rearwardly from the first face 1214. The guide 1210 additionally seats the upper end 1220 of the spindle 1150. The support wire 1170 is operably coupled to the drive assembly 1130 via the bracket 1144. The opposing channels 1230 of the slide 1160 mate with the

rails

1180, 1184 that support the wire 1170 to enable translational movement of the slide 1160 during operation. A first bumper 1234 adjacent the carriage 1144 provides a first travel limit for the slide 1160, and a second bumper 1238 adjacent the guide 1210 provides a second travel limit that defines the range of movement for the slide 1160.

Cable 1250 includes a first end 1254, a second end 1258, and a cable body 1260. The first end 1254 is integrally formed with or secured to a connector 1264, the connector 1264 being coupled to the body of the slider 1160 for movement with the slider 1160. The cable body 1260 extends from the first end 1254 through the guide 1210 toward the top edge 1048 of the basket 1040 and through a passage 1270 defined by a bracket member 1274 generally laterally centrally located near the edge 1048 of the basket 1040. The passage 1270 is formed with an arcuate cable contact portion 1278 so that the cable 1250 rotates about 180 and advances downward in the direction of the lower base member 1052, i.e., the angle between the first and

second ends

1254, 1258 is about 0, but may range from about 0 to about 15. The second end 1258 of the cable 1250 is securely connected to an eyelet 1282, the first end 1286 of the spring 1290 being received through the eyelet 1282, and the second end 1294 of the spring 1290 coupling the spring 1290 to the ring 1190.

As previously discussed for other embodiments, the seat occupant activates the actuator 1130 for the lumbar support mechanism 1100 using an electrically actuated switch preferably positioned adjacent the seat back or seat bottom. Referring to fig. 22 and 24 (and also 25 and 26), when the actuator 1130 is activated, the mechanism 1100 can be in any position between fully retracted (fig. 22) and fully extended (fig. 24). When the motor 1134 is energized, engagement of the worm gear rotates the drive shaft and simultaneously turns the main shaft 1150. If the lumbar support mechanism 1100 is activated to retract, i.e., provide less support, the spindle 1150 rotates in a first direction. If the lumbar support mechanism 1100 is activated to extend, i.e., provide more support, the spindle 1150 rotates in a second, opposite direction. Activation in either direction is user selectable using an electrically actuated switch. Rotation of the spindle 1150 translates the slide 1160, and the channel 1204 of the slide 1160 translates along the

rails

1180, 1184.

To extend the lumbar support mechanism 1100, the seat occupant activates the mechanism to rotate the main shaft 1150 in a second direction, which causes the slider 1160 to move downward toward the base member 1052. As the slider 1160 moves, the cable body 1260 contacts the arcuate portion 1278 of the bracket 1274. Tension between the first and

second ends

1254, 1258 of the cable 1250 acting through the cable body 1260 exerts a downward force on the cradle 1274. Because the brackets 1274 are fixedly secured to the basket 1040 (particularly near the top edges 1048), when the cable 1250 is simultaneously secured to the base member 1052 indirectly by the support wires 1170, the top edges 1048 of the basket 1040, facilitated by the resilient connectors 1044, slide down the

vertical support members

1020, 1024 of the frame portion 1010, extending the lumbar contact area of the basket 1040 forward to support the lumbar region of the seat occupant as shown in fig. 24. When the slider 1160 contacts the bumper 1234, the motor 1134 stops, which stops the rotation of the spindle 1150.

To retract the lumbar support mechanism 1100 to reduce the amount of lumbar support, the seat occupant actuates the mechanism 1100 to rotate the spindle 1150 in a first direction, which causes the slider 1160 to move upward toward the top edge 1048. As the slider 1160 so travels, the pressure from the cable body 1260 against the arch 1278 is relieved and the basket 1040 responsively retracts rearward, which causes the top edge 1048 to flex upward along the

vertical support members

1020, 1024 as further shown in fig. 25 and 26. As previously described, when the slider 1160 contacts the bumper 1238, the motor 1134 stops.

In some applications, the bracket 1274 is replaced by a ledge (not shown) that spans at least a portion of the top edge 1048, preferably in the form of a second rigid wire that presents an attachment surface for the second end 1294 of the spring 1290. With the cable 1250 shorter than that shown and described in fig. 22-26, upon actuation of the motor 1134 to rotate the spindle 1150 and translate the slide 1160, the shorter cable 1250, rather than acting through the cable body 1260 on the bracket 1274 as previously described, acts through the spring 1290 (i.e., the second end 1294) to apply a force directly to the ledge and thus to the top edge 1048 of the basket 1040 to identically extend and retract the basket 1040. In other words, the snap hook 1294 is attached to the rail rather than the loop 1190 on the support wire 1170. Alternatively, in some applications, the second end 1258 of the cable exerts a downward force directly (without the spring 1290) on the top edge 1048 during operation.

Fig. 27 illustrates another lumbar support system 1300 for a vehicle seat having features similar to those of system 1000. For clarity, the system 1300 will be renumbered. The system 1300 includes a self-contained frame portion 1310 having

vertical support members

1320, 1324 for mounting a flexible lumbar support basket 1340. The basket 1340 includes resilient connectors 1344 near a top edge 1348 and

resilient connectors

1350, 1351 near the lower base member 1352 to facilitate travel of the basket 1340 along the

vertical support members

1320, 1324. As shown, the lumbar support system 1300 includes an adjustable lumbar support mechanism 1400.

Referring also to fig. 28, a pair of drive assemblies or

actuators

1430, 1432, similar to the actuator 1130 shown in fig. 22-23, each include a motor 1434, a housing 1442, a carriage 1444, and a worm gear arrangement (not shown) operable for rotating the threaded members or

spindles

1450, 1452 orthogonally to the respective motor drive shafts (not shown), i.e., the

spindles

1450, 1452 are oriented in a generally vertical direction relative to the seat. A slider 1460 having an internally threaded body for engagement with the spindle 1450 is positioned about the threads of the spindle 1450. A block 1462 having an internally threaded body for engagement with the spindle 1452 is positioned about the threads of the spindle 1452.

Rigid support wire 1470 includes: a pair of

hooks

1474, 1476 for engaging with the lower base member 1352; and a first rail section having first and second connected

parallel rails

1480, 1484; and a second rail section having first and second connected

parallel rails

1486, 1488. The first and second end pieces 1500, having semi-circular channels 1504 sized to receive the

guide rails

1180, 1184 and 1186, 1188, respectively, each include a rearwardly extending guide 1510. The guide 1510 of each end piece 1500 additionally seats the

upper end

1520, 1522 of the

respective spindle

1450, 1452. Support wire 1470 is operably coupled to drive

assemblies

1430, 1432 via bracket 1444.

Opposed channels 1530 of sled 1460 mate with

rails

1480, 1484 that support wire 1470 to cause translational movement of sled 1460 during operation. A first bumper 1534 adjacent the bracket 1444 provides a first travel limit for the slide 1460 and a second bumper 1538 adjacent the guide 1510 of the associated end piece 1500 provides a second travel limit that defines the range of movement of the slide 1460.

The opposing channels 1540 of the block 1462 mate with

rails

1486, 1488 that support the wire 1470. The block 1462 includes an aperture 1542 through the block 1462, the aperture 1542 receiving a rail 1544, the rail 1544 being coupled to and extending between the

vertical support members

1320, 1324. The rail 1544 is secured to the

support members

1320, 1324 with straps 1546. Thus, the block 1462 is also fixed relative to the frame portion 1310. As will be described in further detail, first buffer 1548 and second buffer 1549 determine a travel limit associated with block 1462.

Cable 1550 includes a first end 1554, a second end 1558, and a cable body 1560. The first end 1554 is integrally formed with or secured to a connector 1564, the connector 1564 being coupled to the body of the slider 1460 for movement with the slider 1460. The cable body 1560 extends from the first end 1554 through the guide 1510 of the associated end piece 1500 and toward the top edge 1348 of the basket 1340. The cable body 1560 passes through a passage 1570 defined by a bracket member 1574 positioned generally laterally centrally adjacent an edge 1348 of the basket 1340. The passageway 1570 is formed with an arcuate cable contact 1578 such that the cable 1550 rotates about 180 ° and advances downwardly in the direction of the lower base member 1352, i.e., the angle between the first and

second ends

1554, 1558 is about 0 °, but may range from about 0 ° to about 15 °. A second end 1558 of the cable 1550 is securely attached to the hook 1582, receiving the hook 1582 through the aperture 1586 of the end piece 1500 that is in contact with the spindle 1452.

As previously discussed for other embodiments, the seat occupant activates the

actuators

1430, 1432 for the lumbar support mechanism 1400 using an electrically actuated switch preferably positioned adjacent the seat back or seat bottom. Referring to fig. 27 and 29, when the actuator 1430 is activated, the mechanism 1400 can be in any position between fully retracted (fig. 27) and fully extended (fig. 29). Upon energizing the motor 1434 of the actuator 1430, engagement of the worm gear rotates the drive shaft and simultaneously turns the spindle 1450. If the lumbar support mechanism 1400 is activated to retract, i.e., provide less support, the spindle 1450 rotates in a first direction. If the lumbar support mechanism 1400 is activated to extend, i.e., provide more support, the spindle 1450 rotates in a second, opposite direction. Activation in either direction is user selectable using an electrically actuated switch. Rotation of the spindle 1450 translates the slider 1460, and the channel 1504 of the slider 1460 interacts with the

rails

1480, 1484.

To extend the lumbar support mechanism 1400, the seat occupant activates the mechanism to rotate the main shaft 1450 in a second direction, which causes the slider 1460 to move downward toward the base member 1352. As slider 1460 moves, cable body 1460 contacts arcuate portion 1578 of carriage 1574. Tension between the first and

second ends

1554, 1558 of the cable 1550 by the cable body 1560 exerts a downward force on the carriage 1574. Because the brace 1574 is fixedly secured to the basket 1340 (particularly near the top edge 1348), when the cable 1550 is simultaneously secured to the base member 1352 indirectly by the support wire 1470, the top edge 1348 of the basket 1340, facilitated by the resilient connector 1344, slides down the

vertical support members

1320, 1324 of the frame portion 1310, thereby extending the lumbar contact area of the basket 1340 forward to support the lumbar area of the seat occupant as shown in fig. 29. When the sled 1460 contacts the bumper 1534, the motor 1434 of the actuator 1430 stops, which stops the rotation of the spindle 1450.

To retract the lumbar support mechanism 1400 to reduce the amount of lumbar support, the seat occupant activates the mechanism 1400 to rotate the spindle 1450 in a first direction, which causes the slider 1460 to move upward toward the top edge 1348. As the sled 1460 so travels, the pressure from the cable body 1560 against the arch 1578 is relieved and the basket 1340 responsively retracts rearward, which causes the top edge 1348 to flex upward along the

vertical support members

1320, 1324. As previously described, when the sled 1460 contacts the bumper 1538, the motor 1434 of the actuator 1430 is stopped.

Referring to fig. 27 and 30, the support mechanism 1400 and basket 1340 can be vertically adjusted to allow flexibility for a seat occupant to position the basket 1340 as desired. When the actuator 1432 is activated, the mechanism 1400 can be in any position between fully lowered (fig. 27) and fully raised (fig. 30). When the motor 1434 of the actuator 1432 is energized, engagement of the worm gear causes the drive shaft to rotate and simultaneously turn the spindle 1452. If the lumbar support mechanism 1400 is activated to lower, the main shaft 1452 rotates in a first direction. If the lumbar support mechanism 1400 is activated to raise, the spindle 1452 rotates in a second, opposite direction. Activation in either direction is user selectable using an electrically actuated switch. Rotation of spindle 1452 translates mechanism 1400 and basket 1340 relative to fixed block 1462, and channel 1540 of fixed block 1462 interacts with

rails

1486, 1488.

To raise the lumbar support mechanism 1400 and the support 1340, the seat occupant activates the mechanism to rotate the main shaft 1452 in a second direction. The interaction of the threads of the spindle 1452 with the threads of the block 1462 secured to the frame portion 1310 causes the entire mechanism 1400 and basket 1340 to translate upward relative to the block 1462. Without actuation of the additional actuator 1430, the extent of the basket 1340 remains unchanged while tension is maintained within the tension cable 1550. The

connectors

1344, 1350, 1351 operatively contact the

vertical support members

1320, 1324 to permit and guide the upward movement of the basket 1340 to vertically position the lumbar contact area of the basket 1340 as desired. When the bumper 1548 contacts the block 1462, the motor 1434 of the actuator 1432 is stopped, which stops the rotation of the spindle 1452. To lower the lumbar support mechanism 1400, the seat occupant actuates the mechanism 1400 to rotate the spindle 1452 in a first direction, which causes the mechanism 1400 and the basket 1340 to translate downward relative to the block 1462. As previously described, the motor 1434 of the actuator 1432 is stopped when the bumper 1549 contacts the block 1462.

With reference to fig. 30 and 31, basket 1340 is able to be fully retracted and extended at any height within the vertical range determined by

bumpers

1548, 1549 by actuation of actuator 1430 as previously described. Separate operation of the

actuators

1430, 1432 is not required so that vertical adjustment and retraction/extension can be accomplished simultaneously.

Fig. 32-34 illustrate the lumbar support system 2100 referenced relative to the proximal end 2120 and the distal end 2124. The upper and

lower portions

2130, 2134 of the basket 2110 are formed to include a plurality of apertures 2138 separated by reinforcing ribs 2142, the reinforcing ribs 2142 generally connected to one another by a border 2146 on the rear face 2150 of the basket 2110. The basket 2110 includes a mounting surface 2158 in a central portion 2154 between the upper and

lower portions

2130, 2134. The mounting surface 2158 supports the intermediate guide 2162 and the opposing cable passage 2180, the purpose of which will be described below.

The spindle rail 2192 includes a set of upper and lower fins 2196 oriented generally perpendicular to the mounting surface 2158, the mounting surface 2158 including a plurality of corresponding slots 2212. As shown in fig. 34, the tab 2196 and slot 2212 are positioned such that: when assembled, the tabs 2196 protrude through the slots 2212 and then are rotated or bent up or down to permanently secure the spindle rail 2192 to the basket 2110. The lumbar support system 2100 does not use any other fasteners, brackets, or other hardware to secure the spindle rail 2192 to the basket 2110.

The drive assembly or actuator 2230 includes a motor 2234, a housing 2242, and a cap 2250 containing a worm gear and drive shaft, all similar to the actuator 230. The motor 2234 secured to the housing 2242 with the fasteners 2256 is preferably a dc reversible motor, but can be any type of reversible motor suitable for the application and can be further varied in size and power as necessary. A drive shaft (not shown) mates with the worm gear to rotate together and transmit power during operation. The drive shaft terminates in a receiver 2258. The cap 2250 secures the motor 2234 to the spindle rail 2192.

A threaded member or spindle 2260 is coupled to the drive shaft and spans a portion of the spindle rail 2192. The main shaft 2260 has proximal and distal threaded ends 2264, 2268. As shown, the proximal thread is a right-hand thread and the distal thread is a left-hand thread, but in alternative embodiments the chirality can be reversed. The proximal threaded end 2264 is received within an opening 2272 of the receiver 2258, and the proximal threaded end 2264 is rotationally fixed (e.g., by crimping) to the opening 2272, such that the main shaft 2260 rotates with the drive shaft upon actuation of the motor 2234. A travel feature or slide (i.e., a proximal slide 2280 and a distal slide 2284) is positioned about each threaded

end

2264, 2268 of the main shaft 2260. Each

slider

2280, 2284 has: an internally threaded body for engagement with a spindle 2260; and opposing

grooves

2290, 2292, 2294, 2296 that mate with opposing

edges

2300, 2304, respectively, formed as part of the spindle rail 2192. As the spindle rotates, the oppositely threaded spindle ends 2264, 2268, along with the groove/rim interface of the

sliders

2280, 2284 with the spindle rail 2192, cause opposite translational movement of the

sliders

2280, 2284 along the spindle 2260.

A bumper 2308 positioned adjacent to receiver 2258 provides a limit to one end of travel of proximal slider 2280. A spacer 2312 having a proximal end 2314 and a distal end 2316 is positioned about the main shaft 2260 between the

sliders

2280, 2284. Specifically, both bumper 2308 and spacer 2312 include generally smooth inner surfaces without internal threads and are configured to slide or "float" on spindle 2260, i.e., neither bumper 2308 nor spacer 2312 threadingly engage proximal or distal threads of spindle 2260, as will be further explained. The length of the spacer 2312 can vary depending on the particular application, and the particular length can be color coded for reference during system assembly. The spacer 2312 establishes a second travel limit and defines a range of movement for the

slide

2280, 2284.

The proximal and distal

flexible cables

2320, 2324 are coupled to the proximal and

distal sliders

2280, 2284, respectively. Each

cable

2320, 2324 includes a first end 2330, a second end 2334, and a cable body 2338. The first end 2330 has a connector 2344 that fits within the body of a

respective slider

2280, 2284 to move with the

slider

2280, 2284. The cable body 2338 of each

cable

2320, 2324 extends from the first end 2330 and defines an intermediate segment 2350, a portion of the intermediate segment 2350 being located within each respective channel 2180. The middle segment 2350 of the distal cable 2324 of the proximal lumbar support mechanism 2100 is longer than the middle segment 2350 of the proximal cable 2320 of the same lumbar support mechanism. In some embodiments, this longer middle segment 2350 of the cable 2324 is located within a rigid sleeve (not shown) having an inner diameter greater than the diameter of the cable 2324 to allow for free movement of the cable 2324 within the rigid sleeve. The intermediate segment 2350 of each

cable

2320, 2324 terminates at a second end 2334 coupled to a hook fitting 2356.

Referring to fig. 33, the hook fittings 2356 are each configured to pass through a hole 2360 of a hinge 2374 and be secured to an end 2370 of the hinge 2374. Hinge 2374 is a "living" hinge that abuts basket 2110 at both the upper and

lower portions

2130, 2134 on the side opposite end 2370. As shown, hinge 2374 includes a plurality of pivot points positioned to prevent interference with motor 2234 during the course of travel of basket 2110. Hinge 2374 and basket 2110 are preferably formed as a unitary piece. Alternatively, hinge 2374 can be a separate piece that is secured to basket 2110 in a manner known to those skilled in the art. Each end 2370 of the hinge 2374 includes a pair of flexible snap hooks 2380 that are configured to be connected to a portion of the respective

vertical support members

34, 38 of the frame 26 (see, e.g., fig. 1). Although not shown, a spring coupled in series with one or both of the

cables

2320, 2324 can allow for a limited amount of deflection and provide an occupant with a "give" to enhance the comfort of the device.

The previously described mounting of the spindle rail 2192 to the basket 2110 serves as the only way to secure the aforementioned components of the lumbar support system 2100 (except for the basket 2110) to the vehicle.

In operation, the seat occupant activates the electrical actuator 2230 using an electrically actuated switch. Operation proceeds similarly to the lumbar support system 100 (i.e., between the fully retracted position and the fully extended position). If the lumbar support system 2100 is activated to retract the basket 2110, the spindle 2260 rotates in a first direction. If the lumbar support system 2100 is activated as the extension basket 2110, the spindle 2260 rotates in a second, opposite direction. Activation in either direction is user selectable using an electrically actuated switch. Due to the interaction of the

grooves

2290, 2292, 2294, 2296 of the

sliders

2280, 2284 with the

edges

2300, 2304 of the spindle rail 2192, rotation of the spindle 2260 translates the

sliders

2280, 2284, one of the

sliders

2280, 2284 travels in the proximal direction (2120), and the other of the

sliders

2280, 2284 travels in the distal direction (2124).

If the occupant desires to extend the basket 2110 to provide more lumbar support, clockwise rotation of the spindle 2260 (as viewed from the distal direction 2124) causes the proximal slider 2280 to travel distally along the spindle 2260 and the distal slider 2284 to travel proximally along the spindle 2260, i.e., the

sliders

2280, 2284 and their

respective attachment cables

2320, 2324 approach one another. As the

slides

2280, 2284 converge, a portion of the middle section 2350 of each cable slides within their respective channel 2180, contacting the basket 2110. This contact creates a force that guides the basket forward against the basket 2110. During initial movement of the proximal slider 2280 in the distal direction, the proximal slider 2280 contacts the proximal end 2314 of the spacer 2312 and simultaneously moves the spacer 2312 distally. When the distal end 2316 of the spacer 2312 contacts the distal slider 2284, the motor 2234 stops, thereby stopping rotation of the main shaft 260. Other methods of de-energizing the motor 2234 at some point of travel known to those skilled in the art can also be used by the lumbar support system 2100. Hinges 2374 anchored to respective vertical support members facilitate movement of the baskets 2110 by flexing to provide smooth motion throughout the range of travel.

If the occupant desires the basket 2110 to be retracted to reduce the amount of lumbar support, counterclockwise rotation of the spindle 2260 causes the proximal slider 2280 to travel proximally along the spindle 2260 and the distal slider 2284 to travel distally along the spindle 2260, i.e., the

sliders

2280, 2284 and their

respective attachment cables

2320, 2324 are disengaged. As the

sliders

2280, 2284 move away, the pressure against the basket 2110 from the middle segment 2350 of the cable is relieved and the basket 2110 retracts rearward in response. When the slide 2280 contacts the bumper 2308, the motor 2234 stops as previously described. During subsequent movement of the

slides

2280, 2284, the spacers 2312, which are free floating along the quill 2260, are generally held in place midway between the

slides

2280, 2284.

During travel of the basket 2110, from retracted to extended and from extended to retracted, the

cables

2320, 2324 remain disposed in substantially the same plane, and the angle α (see fig. 4) between the first and

second ends

2330, 2334 of each

cable

2320, 2324 remains obtuse.

Fig. 35-37 illustrate the modular nature of the lumbar support system 2100. The basket 2110 is configured to support the spindle rail 2192 at both proximal and distal locations on the mounting surface 2158, and the actuator 2230 can be mounted to the spindle rail 2192 in two possible orientations. Thus, as shown, the system 2100 can be configured in four possible ways depending on the vehicle parameters or constraints of a particular application.

Fig. 38-39 illustrate another lumbar support system 2400 for use with a seat, such as the seat 410 shown in fig. 6, having a contoured or deflection pad 440. The lumbar support system 2400 is similar to the lumbar support system 2100 with certain differences described below.

The drive assembly or actuator 2430 is substantially similar to the actuator 2230 and need not be described in further detail. The threaded member or spindle 2460 coupled to the drive shaft of the actuator 2430 spans a substantial portion of the spindle guide 2462. The spindle guide 2462 includes an attachment bracket or attachment portion 2466 adjacent the actuator 2430 having first and second slots 2470 as best shown in fig. 39. The inner perimeter 2472 of one or both of the slots 2470 is lined with a plurality of continuous or non-continuous burrs, ridges, or similar projections. In one embodiment, outer filaments 444 of deflection pad 440 comprise a thin coating of nylon or nylon equivalent, which may be on the order of about 0.4mm in thickness. During assembly, and particularly during coupling of attachment 2466 to an associated outer wire 444, attachment 2466 is positioned such that slot 2470 comes into contact with wire 444, i.e., snaps into place, such that burrs on inner periphery 2472 "bite" into the coating. This coupling between the attachment portion 2466 and the outer wire 444 allows the spindle guide 2462 to rotate about the outer wire 444, but resists movement of the spindle guide 2462 along the outer wire 444. Also, without the use of additional tools or tooling, the attachment portion 2466 can be disengaged from the outer wire 444 and moved to another location along the length of the outer wire 444 and coupled again to adjust the position of the support system 2400 relative to the deflection pad 440 and the seat 410.

The main shaft 2460 has right-hand proximal and left-hand distal threads and corresponding proximal and

distal sliders

2480, 2484. A bumper 2508 positioned adjacent to the drive shaft of the actuator 2430 provides a first limit of travel for the proximal slider 2480. A spacer 2512 having a proximal end 2514 and a distal end 2516 is positioned around the main shaft 2460 between the

sliders

2480, 2484. The spacer 2512 is identical to the spacer 2312, and the spacer 2512 is configured to "float" on the main shaft 2460 while establishing the second limit of travel, and the spacer 2512 defines a range of movement of the

sliders

2480, 2484.

Proximal and

distal pull cables

2620, 2624 are coupled to proximal slider 2480 and distal slider 2484, respectively. Each

cable

2620, 2624 includes a cable body 2638 and is coupled to a

respective slider

2480, 2484. The intermediate segment 2650 of the distal cable 2624 is longer than the corresponding intermediate segment 2650 of the proximal cable 2620. As shown, a portion of this longer segment of the cable 2624 is located within a rigid sleeve 2652, the rigid sleeve 2652 having an inner diameter larger than the diameter of the cable 2624 to allow the cable 2624 to move freely within the rigid sleeve 2652. A portion of each of the proximal and

distal cables

2620, 2624 passes through the clip 2660 and is contained by the clip 2660, the clip 2660 coupling the proximal and

distal cables

2620, 2624 to the deflection pad 440 via the outer wire 444. The

cables

2620, 2624 each terminate at a hook fitting 2668, the hook fitting 2668 itself being fixed to the respective

vertical support part

434, 438 of the frame 426 (see fig. 6).

Mounting the spindle rail 2462 to the flex pad 440 via the attachment portion 2466 and the clip 2660 as previously described serves as the sole way to secure the aforementioned components of the lumbar support system 2400 to the vehicle.

Using an electrically actuated switch preferably located adjacent the seat back 418 or seat bottom 414, the seat occupant activates the actuator 2430 for the lumbar support system 2400. When the actuator 2430 is activated, the system 2400 can be in any position between the fully retracted position and the fully extended position. Energizing actuator 2430 rotates spindle 2460 in the same manner as actuator 2230 rotates spindle 2260 to translate

sliders

2480, 2484. As the

sliders

2480, 2484 converge, the intermediate segment 2650 contacts the laterally outer wire 444, forcing the deflection pad 440 forward. During initial movement of the proximal slider 2480 in the distal direction, the proximal slider 2480 contacts the proximal end 2514 of the spacer 2512 and simultaneously moves the spacer 2512 distally. When the distal end 2516 of the spacer 2512 contacts the distal slider 2484, the actuator 2430 stops, stopping rotation of the main shaft 2460. The hook fitting 2668 allows for coupled rotation about the

vertical support components

434, 438 to allow for smooth movement of the lumbar support system 2400 as the lumbar support system 2400 travels forward.

Because the spindle guide 2462 is not coupled to the center wire 448 of the flex pad 440 but is able to rotate about the attached outer wire 444, the center wire 448 is allowed to "flex" more during operation and the user is less prone to feeling the presence of the spindle guide 2462.

To retract the lumbar support system 2400 to reduce the amount of lumbar support, the seat occupant actuates the actuator 2430 to rotate the spindle 2460 counterclockwise, which causes the proximal slider 2480 to travel proximally and the distal slider 2484 to travel distally. As the

sliders

2480, 2484 move farther apart, the pressure from the middle segment 2650 of the

cables

2620, 2624 against the laterally outer wire 444 is relieved and the deflection pad 440 retracts rearward. As previously described, the motor 534 stops when the proximal slider 2480 contacts the bumper 2508.

As with the lumbar support system 2100, during the course of travel of the contour pad 440, from retracted to extended and from extended to retracted, the

cables

2620, 2624 remain disposed in substantially the same plane, and the angle β (see, e.g., fig. 9) between the first and second ends of each

cable

2620, 2624 remains obtuse.

Fig. 40-42 illustrate the modular nature of the lumbar support system 2400. The flex pad 440 is configured to support the spindle guide 2462 at either of the outer wires 444, and the actuator 2430 can be mounted to the spindle guide 2462 in two possible orientations. Thus, as shown, system 2400 can be configured in four possible ways depending on the vehicle parameters or constraints of a particular application.

The members of the lumbar support system of fig. 1, 6, 13, 14, 22, 27, 32, and 38 can be constructed of metal, plastic, or a combination of both, e.g., the

main shaft

260, 560, 860, 1150, 1450, 1452, 2260, 2460 and the

main shaft rail

192, 562, 862, 2192, 2462 can be formed of metal, such as aluminum, with the remaining members being formed of plastic.

Claims

1. An adjustable support system for a seat having a frame, the adjustable support system comprising:

a contour pad movable relative to the frame from a first position to a second position, wherein the contour pad comprises a pair of spaced-apart laterally outer filaments and a plurality of transverse filaments extending between the pair of spaced-apart laterally outer filaments;

an actuator comprising a motor;

a threaded member coupled to a drive shaft of the actuator and movable by the motor, wherein the threaded member has a length and the threaded member spans a substantial portion of a spindle guide, and the spindle guide includes an attachment portion in the vicinity of the actuator, the attachment portion having a first slot and a second slot, and the attachment portion being capable of being coupled to and decoupled from the laterally outer wire and moved to another location along the length of the laterally outer wire and coupled again;

a distal cable having a first end and a second end, the first end of the distal cable being coupled to a distal slider for movement along the length of the threaded member, the distal slider being positioned about one threaded end of the threaded member, and the distal slider having an internally threaded body for engagement with the threaded member; and

a proximal cable having a first end and a second end, the first end of the proximal cable being coupled to a proximal slider for movement along the length of the threaded component, the proximal slider being positioned about another threaded end of the threaded component, and the proximal slider having an internally threaded body for engagement with the threaded component,

wherein the second end of the proximal cable and the second end of the distal cable are each coupled to a hook fitting,

wherein movement of the threaded member by the motor causes the distal cable and the proximal cable to move the profile pad relative to the frame between the first position and the second position, and

wherein the threaded component has a right-hand proximal thread and a left-hand distal thread and the proximal slider and the distal slider, respectively.

2. The adjustable support system of claim 1, wherein the motor moving the threaded member causes the first end of the distal cable and the first end of the proximal cable to move in opposite directions along the length of the threaded member.

3. The adjustable support system of claim 1, wherein the motor moves the threaded member causing contact between a portion of the distal cable and the profile pad and a portion of the proximal cable and the profile pad to move the profile pad relative to the frame from the first position to the second position, wherein the portion of the distal cable is intermediate the first and second ends of the distal cable and the portion of the proximal cable is intermediate the first and second ends of the proximal cable.

4. The adjustable support system of claim 3, wherein a portion of the longer segment of the distal cable is located within a rigid sleeve having an inner diameter greater than a diameter of the distal cable to allow the distal cable to move freely within the rigid sleeve.

5. The adjustable support system of claim 1, wherein the contour pad is configured to support the spindle rail at either of the laterally outer wires, and the actuator is mountable to the spindle rail in two possible orientations.

6. The adjustable support system of claim 1, wherein the attachment portion is capable of being disengaged from the laterally outer wire and moved to another position along the length of the laterally outer wire and re-coupled without the use of additional tools or tooling in order to adjust the position of the adjustable support system relative to the contoured pad and the seat.

7. The adjustable support system of claim 1, wherein the first and second slots are configured to contact and disengage from the laterally outer wire of the profile pad.

8. The adjustable support system of claim 7, wherein the coupling between the attachment portion and the laterally outer wire allows the spindle rail to rotate about the laterally outer wire and resists movement of the spindle rail along the laterally outer wire.

9. The adjustable support system of claim 7, wherein the coupling between the attachment portion and one of the pair of spaced apart laterally outer wires allows the spindle rail to rotate about the one laterally outer wire and resists movement of the spindle rail along the one laterally outer wire.

10. The adjustable support system of claim 9, wherein a portion of the distal cable passes through and is contained by a clip that couples the distal cable to the profile pad through the laterally outer wire and terminates at a hook fitting that is secured to a corresponding vertical support component of the frame.

11. The adjustable support system of claim 7, wherein the attachment portion is a bracket and the slot is configured to snap over the laterally outer wire.

12. The adjustable support system of claim 1, wherein the hook fitting is secured to a corresponding vertical support component of the frame.