Power seat recliner

Claim 2

A motor vehicle power seat recliner comprising: an upper recliner structure for supporting a seat back cushion, a lower recliner structure for supporting a seat bottom cushion, first pivot means for enabling the reclined angle between said upper and lower recliner structure to be adjusted, a toothed quadrant coupled to said upper recliner structure, an electric motor having an elongated casing with first and second axial ends, with a drive shaft extending from said first end, said lower recliner structure supporting said motor adjacent both said first and second ends, a worm gear affixed to said drive shaft and fixed thereto for rotation, and gear train means for providing a gear reduction and for communicating rotation of said drive shaft to said toothed rack, said gear train means including a plurality of gears consecutively intermeshed and each having a larger diameter toothed section for driving an adjacent gear through its smaller diameter toothed section, one of said gears meshed with said worm gear and another of said gears driving said toothed quadrant whereby rotation of said drive shaft causes the reclined angle between said upper and lower recliner structures to be varied.

Claim 3

A motor vehicle power seat recliner according to claim 1 whereby said drive shaft is rotationally compliant thereby absorbing shock loads acting on said motor and said gear train means.

Claim 4

A motor vehicle power sear recliner according to claim 1 further comprising a housing carrying a gear which meshes with said worm gear and a pair of worm gear supports and said housing being mounted to said lower recliner structure.

Claim 5

A motor vehicle power seat recliner comprising: an upper recliner structure for supporting a seat back cushion, a lower recliner structure for supporting a seat back cushion, first pivot means for enabling the reclined angle between said upper and lower recliner structures to be selectively varied, a toothed quadrant coupled to said upper recliner structure having its center at said first pivot means, motion limiting means associated with one of said upper and lower recliner structures for limiting the maximum range of angular motion of said upper recliner structure relative to said lower recliner structure about said first pivot means, an electric motor having an elongated casing with first and second axial ends and having a drive shaft extending from said first end, said lower recliner structure supporting said electric motor adjacent both said first and second axial ends, a worm gear affixed to said drive shaft for rotation therewith, gear train means for providing a gear reduction and for communicating rotation of said drive shaft to said toothed quadrant whereby rotation of said drive shaft causes the reclined angle between said upper and lower recliner structures to be selectively varied, said gear train means including at least three gear sets for meshingly interconnecting said drive shaft to said toothed quadrant, each of said at least three gear sets including a first toothed section having a larger diameter and a second toothed section having a smaller diameter such that said smaller diameter section meshes with said larger diameter section of an adjacent gear set, and compliant means for absorbing torsional shock loads acting on said worm gear upon actuation of said electric motor.

Claim 6

A motor vehicle power seat recliner comprising: an upper recliner structure for supporting a seat back cushion, a lower recliner structure for supporting a seat back cushion, first pivot means for enabling the reclined angle between said upper and lower recliner structures to be selectively varied, a toothed quadrant coupled to said upper recliner structure having its center at said first pivot means, motion limiting means associated with one of said upper and lower recliner structures for limiting the maximum range of angular motion of said upper recliner structure relative to said lower recliner structure about said first pivot means, an electric motor having an elongated casing with first and second axial ends and having a drive shaft extending from said first end, said lower recliner structure supporting said electric motor adjacent both said first and second axial ends, a worm gear affixed to said drive shaft for rotation therewith, gear train means for providing a gear reduction and for communicating rotation of said drive shaft to said toothed quadrant whereby rotation of said drive shaft causes the reclined angle between said upper and lower recliner structures to be selectively varied, said gear train means including at least three gear sets for meshingly interconnecting said drive shaft to said toothed quadrant, each of said at least three gear sets including a first toothed section having a larger diameter and a second toothed section having a smaller diameter such that said smaller diameter section meshes with said larger diameter section of an adjacent gear set, and compliant means for absorbing torsional shock loads acting on said worm gear upon actuation of said electric motor.

Claim 7

A motor vehicle power seat recliner according to claim 4 wherein said motion limiting means comprises a pin member affixed to one of said upper and lower recliner structures and an accurate slot in the other thereof, said pin member confined for limited angular movement within said slot.