Adjustable lumbar support with extensive configurability

Abstract

An adjustable lumbar support for a seat having a seat frame is disclosed, the adjustable lumbar support including a floating support plate for providing an amount of lumbar support to a lumbar region of a seat, the support plate having a front surface and a rear surface, the floating support plate being attached to the seat frame via springs, the provided lumbar support defining an apex. A first actuator assembly and a second actuator assembly are each operatively connected to the floating support plate via respective first and second cables, the first and second cables being spaced from each other substantially vertically within the floating support plate, the first and second actuator assemblies for selectively actuating the respective cables to selectively move the apex substantially vertically and substantially horizontally forward and back relative to the seat frame. A secondary support plate may be provided, and may be hingedly and/or floatingly mounted. Adjustability may be achieved in terms of back and forth (horizontally), up and down (vertically) and by the vertical height of the lumbar support profile. Accordingly, in some aspects the present invention provides a “six-way” adjustable lumbar support.

1 . An adjustable lumbar support for a seat having a seat frame, the adjustable lumbar support comprising: 
 a laterally rigid floating support plate for providing support to a lumbar region of a seat, the support plate having a front surface and a rear surface;    a first support linkage and a second support linkage for supporting the floating support plate, the first support linkage being disposed laterally upward from the second support linkage along the floating support plate, wherein each support linkage is adapted for engaging the seat frame and has an effective length and at least one spring member disposed between the floating support plate and the seat frame, each support linkage supporting the floating support plate in a pivotal manner; and    an actuator for selectively adjusting the effective length of either or both of the first and second support linkages, whereby an amount of lumbar support provided by the floating support plate is increased as the effective length of the first or second support linkage is decreased via the movement of the floating support plate relative to the support frame.    
   
   
       2 . The adjustable lumbar support of  claim 1 , wherein the first support linkage is defined by a first cable member and first spring member, wherein the first spring member is adapted for engaging the seat frame, wherein the first cable member has a first end secured to the actuator and a second end secured to the first spring member, the first cable member sliding in a cable housing secured to the rear surface of the floating support plate.  
   
   
       3 . The adjustable lumbar support of  claim 2 , wherein the second support linkage is defined by a second cable member and second spring member, wherein the second spring member is adapted for engaging the seat frame, wherein the second cable member has a first end secured to the actuator and a second end secured to the second spring member, the second cable member sliding in a cable housing secured to the rear surface of the floating support plate.  
   
   
       4 . The adjustable lumbar support of  claim 1 , further including a secondary support plate mounted within the seat frame and pivotally connected to the floating support plate, the secondary support plate being floatingly positionable relative to the seat frame when the actuator is operated, thereby allowing for a larger amount of lumbar support.  
   
   
       5 . The adjustable lumbar support of  claim 4 , wherein the secondary support plate is located above the floating support plate within the seat frame.  
   
   
       6 . The adjustable lumbar support of  claim 4 , wherein the secondary support plate is secured to the seat frame by spring members.  
   
   
       7 . The adjustable lumbar support of  claim 4 , wherein the secondary support plate is hingedly connected to the lower support plate.  
   
   
       8 . The adjustable lumbar support of  claim 1 , wherein the floating support plate is molded in a seatback foam cushion attached to the seat frame.  
   
   
       9 . The adjustable lumbar support of  claim 1 , wherein the floating support plate and a seatback foam cushion attached to the seat frame include a plurality of cooperating structures for attaching the floating support plate to the foam cushion.  
   
   
       10 . The adjustable lumbar support of  claim 1 , wherein the floating support plate has a curved front surface.  
   
   
       11 . The adjustable lumbar support of  claim 1 , wherein the floating support plate is constructed of a substantially rigid material such that the floating support plate does not flex when loaded by an occupant.  
   
   
       12 . The adjustable lumbar support of  claim 1 , wherein the actuator includes a first actuator mechanism operatively associated with the first support linkage and a second actuator mechanism operatively associated with the second support linkage.  
   
   
       13 . The adjustable lumbar support of  claim 12 , wherein the first and second actuator mechanisms each include an electrical motor.  
   
   
       14 . The adjustable lumbar support of  claim 13 , wherein the electrical motors are mounted to the seat frame.  
   
   
       15 . The adjustable lumbar support of  claim 1 , wherein the amount of lumbar support defines an apex, the apex being selectively movable substantially vertically and substantially horizontally forward and back relative to the seat frame by manipulation of the first and second actuating mechanisms.  
   
   
       16 . The adjustable lumbar support of  claim 1 , wherein the amount of lumbar support provided has a vertical height, and the vertical height is selectively increasable or decreasable via the first and second actuating mechanisms.  
   
   
       17 . A seat assembly including a seat frame and an adjustable lumbar support as in  claim 1 .  
   
   
       18 . An adjustable lumbar support for a seat having a seat frame, the adjustable lumbar support comprising: 
 a floating support plate for providing support to a lumbar region of a seat, the support plate having a front surface and a rear surface;    a first support linkage and a second support linkage for supporting the floating support plate, the first support linkage being disposed laterally upward from the second support linkage along the floating support plate, wherein each support linkage is adapted for engaging the seat frame and has an effective length and at least one spring member disposed between the floating support plate and the seat frame, each support linkage supporting the floating support plate in a pivotal manner;    a first actuator mechanism for selectively adjusting the effective length of the first support linkage and a second actuator mechanism for selectively adjusting the effective length of the second support linkage, whereby an amount of lumbar support provided by the floating support plate is increased as the effective length of the first or second support linkage is decreased via the movement of the floating support plate relative to the support frame; and    a secondary support plate floatingly mounted within the seat frame and pivotally connected to the floating support plate, the secondary support plate being positionable relative to the seat frame when the actuator is operated, thereby allowing for an amount of lumbar support to be provided by the secondary support plate.    
   
   
       19 . The adjustable lumbar support of  claim 18 , wherein the first and second actuator mechanisms each include respective electrical motors, and the first and second support linkages each include respective Bowden cables.  
   
   
       20 . The adjustable lumbar support of  claim 18 , wherein the secondary support plate is mounted to the seat frame via spring members vertically above the floating support plate within the seat frame.  
   
   
       21 . The adjustable lumbar support of  claim 18 , wherein the floating support plate and the secondary support plate define a width and a height greater than about one-third of the respective horizontal and vertical space between opposite side members of the seat frame.  
   
   
       22 . The adjustable lumbar support of  claim 18 , wherein the floating support plate and the secondary support plate provide lumbar support defining an apex, the apex being selectively movable substantially vertically and horizontally forward and back relative to the seat frame by manipulation of the first and second actuating mechanisms.  
   
   
       23 . The adjustable lumbar support of  claim 18 , wherein the amount of lumbar support provided has a vertical height, and the vertical height is selectively increasable or decreasable via the first and second actuating mechanisms.  
   
   
       24 . A seat assembly including a seat frame and an adjustable lumbar support as in  claim 18 .  
   
   
       25 . An adjustable lumbar support for a seat having a seat frame, the adjustable lumbar support comprising: 
 a floating support plate for providing support to a lumbar region of a seat, the support plate having a front surface and a rear surface, the floating support plate being attached to the seat frame via springs;    a secondary support plate mounted within the seat frame substantially vertically adjacent to the floating support plate and pivotally connected to the floating support plate, the secondary support plate being attached to the seat frame via springs; and    a first actuator assembly and a second actuator assembly each operatively connected to the floating support plate via respective first and second Bowden cables, the first and second Bowden cables being spaced from each other substantially vertically within the floating support plate, the first and second actuator assemblies for selectively actuating the respective Bowden cables to alter an amount of lumbar support provided by the floating support plate and secondary support plate.    
   
   
       26 . The adjustable lumbar support of  claim 25 , wherein the floating support plate and the secondary support plate provide lumbar support defining an apex, the apex being selectively movable substantially vertically and substantially horizontally forward and back relative to the seat frame by manipulation of the first and second actuating mechanisms.  
   
   
       27 . The adjustable lumbar support of  claim 25 , wherein the amount of lumbar support provided has a vertical height, and the vertical height is selectively increasable or decreasable via the first and second actuating mechanisms.  
   
   
       28 . A seat assembly including a seat frame and an adjustable lumbar support as in  claim 25 .  
   
   
       29 . An adjustable lumbar support for a seat having a seat frame, the adjustable lumbar support comprising: 
 a laterally rigid floating support plate for providing an amount of lumbar support to a lumbar region of a seat, the support plate having a front surface and a rear surface, the floating support plate being attached to the seat frame via springs, the provided lumbar support defining an apex; and    a first actuator assembly and a second actuator assembly each operatively connected to the floating support plate via respective first and second cables, the first and second cables being spaced from each other substantially vertically within the floating support plate, the first and second actuator assemblies for selectively actuating the respective cables to selectively move the apex substantially vertically and substantially horizontally forward and back relative to the seat frame.    
   
   
       30 . The adjustable lumbar support of  claim 29 , wherein the amount of lumbar support provided has a vertical height, and the vertical height is selectively increasable or decreasable via the first and second actuating mechanisms.  
   
   
       31 . The adjustable lumbar support of  claim 29 , further including a secondary support plate mounted within the seat frame substantially vertically adjacent to the floating support plate and pivotally connected to the floating support plate, the secondary support plate being attached to the seat frame via springs.  
   
   
       32 . A seat assembly including a seat frame and an adjustable lumbar support as in  claim 29.