The invention relates generally to a folding belt positioning juvenile booster car seat that folds compactly for easy transportation, thereby reducing shipping costs as well as physical space requirements at the retail level.

Passenger restraint systems in automobiles are generally well suited to properly restrain adults but not well suited to properly restrain children. Accordingly, vehicle restraint systems must be supplemented by devices such as booster seats, which may be broadly defined as a seat that relies primarily on the vehicle's lap and shoulder belts to retain the seat in the vehicle and to restrain the child's torso. These seats include a seat portion to elevate the child above the vehicle's seating surface to a position in which the vehicle's shoulder belt is better positioned on the child and which properly positions the vehicle lap belt on the child's torso, and may also include a back portion. A common construction technique for booster seats with backs is to mold the seat and back portions from rigid plastic and cover them with a cushion or pad.

Known booster seat designs suffer from several drawbacks. First, the large L-shaped bodies tend to be relatively expensive and difficult to mold in one piece, especially if the seat includes wings and a lap belt path. Additionally, these booster seat designs suffer from a large size which is difficult to ship, store, package for manufacturers, and difficult to store and transport for consumers.

The manufacturing expense associated with a rigid molded body derives from the complex molding process required. One solution is to mold the seat as a plurality of separate, less complex, pieces and assemble the separate pieces into a rigid whole. Unfortunately, molding the seat as separate pieces requires additional tooling to mold the separate pieces and adds assembly steps, both of which add to the cost of manufacture. Thus, the savings due to less complex molding is offset by increased manufacturing and assembly costs and the seat is still large and bulky.

Therefore, what has been lacking in the industry is an easy to manufacture L-shaped car seat which is easily collapsed or foldable from an L-shaped position to a more compact position for ease of transportation and storage, yet which can be similarly, easily unfolded to its L-shaped use position.

DE 41 37 599 A1 discloses a child seat for a car. The child seat consists of a seat assembly and a back assembly attachable to the seat assembly. The back assembly can be adjusted as regards height and inclination.

Another child seat for a car is disclosed in US-A-5 845 967 .

The present invention provides a car seat which comprises:

1. (a) a seat member having a top and a bottom and a pair of curvilinear bottom sides;
2. (b) a back member having a front and a back pivotally connected to said seat member, said back member having a pair of curvilinear seat back sides; and
3. (c) means for selectively positioning and maintaining said seat member and back member relative to each other in an essentially L-shaped first position, characterized in that:
   • the car seat is collapsible;
   • said curvilinear bottom sides are raised with respect to said seat member,
   • said curvilinear seat back sides are raised with respect to said back member,
   • said means for selectively positioning and maintaining said seat member relative to said back member is also arranged to selectively position and maintain said seat member in a second essentially collapsed position wherein said top of said seat member is adjacent to said front of said back member, and
   • the curvilinear shape of said bottom sides is essentially duplicated by the curvilinear shape of said seat back sides in order to minimize space requirements of the car seat when in said collapsed position.

The general configuration for a belt-positioning booster car seat is typically a molded plastic seat with a back and a seating surface. These surfaces have adjacent side walls that help contain and protect the child occupant. Slots or recesses on both sides of the seat in the occupants' hip area receive the lap belt portion of an auto belt restraint. Hooks or slots on both sides of the seat on the head/shoulder area receive the shoulder belt portion of the auto restraint in multiple height positions. The booster seat positions the auto belts to properly restrain the small occupant. The shoulder belt is especially important and the clips or slots on the shoulder area of the booster, when used properly, guide the belt across the occupants' shoulder and not on the head or neck. The lap belt is equally important and the slots in the hip area guide the lap belt across the bony pelvis, not the soft abdomen area.

This folding booster is comprised of two main molded components, the seat and back sections. They are joined at a main pivot directly behind and slightly above the lap belt recesses. This pivot allows the back and seat sections to fold toward each other, permitting the seat to be transported more easily than a non-folding seat because of the smaller size. This reduction in size requires a package roughly half the size of a typical non-folding seat, which is very beneficial for packaging and freight cost savings as well as minimizing retail shelf space at the consumer store location.

Two spring-biased latches located on each side of the back section, just above the main pivot maintain the back and seat in a folded or unfolded position. The latches engage recesses molded into hubs on the seat section that are configured concentrically around the hub and the main pivot. The latches and surrounding structure are shaped such that the user must grip the latch and the surrounding area of the seat back section at the same time. Squeezing the latch compresses the spring and disengages the hub. Both latches must be disengaged at the same time to release the hubs which rotate freely as long as the latches are depressed. Since the act of releasing the hubs involves gripping the seat and latches simultaneously, folding is very easy as the user already has a grip on the seatback and can readily maneuver it.

As the seat back folds toward the seating surface, the latches engage, via the springs, different recesses in the hubs, holding the seat in its folded position. To unfold the seat to the usable position, both latches must be depressed simultaneously and the seat and back sections can be rotated away from each other to their original position.

When the seat is in the folded position, it can stand on its own and be carried like a suitcase with a handle molded into the top of the seatback. Alternatively, the carrier can grip the folded seat under the front bottom edge of the seat section or with the folded seat turned on its side, under either armrest portion of the seat section.

In one aspect of the present invention, the foldability of the car seat permits ease of transportation, economical packaging, shipping and low retail shelf space requirements and consumer benefits from the standpoint of ease of transporting the car seat from location to location.

These and other objects of the present invention will become more readily apparent from a reading of the following detailed description taken in conjunction with the accompanying drawings wherein like reference numerals indicate similar parts, and with further reference to the appended claims.

The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

• FIG. 1 is a front perspective view of a foldable car seat;
• FIG. 2 is a rear perspective view of the foldable car seat of FIG. 1;
• FIG. 3 is a front perspective view of the car seat of FIG. 1 in a collapsed position;
• FIG. 4 is a rear perspective view of the cars seat of FIG. 1 in a collapsed position;
• FIG. 5 is a side elevational view of the car seat of FIG. 1 shown in a collapsed position with the latch mechanism shown in cross-section;
• FIG. 6 is a side elevational view of the car seat of FIG. 5 shown in an open position with the latch mechanism shown in cross-section;
• FIG. 7 is a front perspective view of an alternative embodiment of the invention showing a bottom mounted latch release;
• FIG. 7a is a perspective view of an alternative embodiment of a hinge connecting the two portions of the car seat;
• FIG. 8 is a side elevational view of FIG. 7 in partial cut-away showing the bottom mounted latch release;
• FIG. 9 is a side elevational view of an alternative embodiment of the invention showing a top mounted latch release in partial cut-away;
• FIG. 10 is a side elevational view of an alternative embodiment of the invention showing a top mounted latch release which uses a rocker arm;
• FIG. 11 is a side elevational view of an alternative embodiment of the invention showing a button release latch;
• FIG. 12 is an enlarged cross-sectional view of the button release latch of FIG. 11 taken along line A-A;
• FIG. 13 is an enlarged cross-sectional view of the button release latch of FIG. 12 taken along line B-B;
• FIG. 14 is side elevational view of an alternative embodiment of the invention showing a button release latch positionable into one of two different locations;
• FIG. 15 is an enlarged cross-sectional view of the button release latch of FIG. 14 taken along line A-A; and
• FIG. 16 is an enlarged perspective view of the release latch positionable into one of two different locations of FIG. 14.

Referring now to the drawings wherein the showings are for purposes of illustrating the preferred embodiment of the invention only and not for purposes of limiting the same, FIGS. 1 through 6 show one embodiment of this invention wherein depression of a pair of pivotable handles selectively permit pivotable rotational movement from a first position into a second position, thereby collapsing or folding the car seat. The car seat 10 has a back member 14 and a seat member 12, the two members pivotally connected by main pivot pin 38. Back member 14 further comprises a seat back 18, a pair of raised seat back sides 16, a slightly raised top ledge 24 and a seat back bottom edge 54. Each seat back side 16 is generally hollow having an exterior side 62, a top side 60 and an interior side 61, said hollow interior being generally contiguous with top ledge 24. Optionally, a plurality of ribs are interspersed between the interior 61 and exterior 62 sides for additional structural integrity. In this embodiment, each seat back side 16 has a yoke portion 56 for accommodating pivotal rotational movement of a yoke insertion member 44 and permitting top side portion 66 of seat member raised side portion 50 to be positioned in close proximity to raised seat back sides 16 by clockwise rotational movement of seat member 12 toward back member 14. Phrased alternatively, and equivalently, the rotational movement may be thought of as counterclockwise if back member 14 is rotated toward seat member 12.

Each seat back side 16 has a seat belt guiding device 32 affixed to an upper portion of exterior side 62. Each guiding device has a pair of inwardly facing hook-like members 58 at opposed ends of the device defining at least one slot. Optionally and preferably, the device will have at least one T-shaped member 34 between said hook-like members for defining a slot into which a shoulder belt (not shown) may be inserted so as to properly be located upon an occupant seated in the car seat. Optionally, shoulder belt guiding device may be configured so as to permit vertical axial sliding movement on seat back sides 16. Additionally, the lap belt is guided and positioned appropriately on a user's pelvic area by recessed areas 66 on either side of seat member 12.

Seat member 12 further comprises a curvilinear seat bottom 20, a pair of raised bottom sides 22, each side generally being hollow and having an exterior side 50, a front top side 22, a lowered or recessed rear top side 66, an interior side 64, a front 26 and a rear 52. At the base of seat member 12 is a pair of front leg members 30 and a pair of rear leg members 28, each of the rear leg members having a back member 46 for physical contact with a surface for standing when seat member 12 is rotated into a collapsed position in conjunction with base 150 of seat member 14 illustrated in FIG. 5. Seat member 12 optionally has a recessed and cut-out portion 48.

Each seat back side 16 of seat back member 14 additionally has a rotatable latch handle 42 pivotable about latch handle pivot pin 40 which is biased in a normally outward position. Positioned within yoke 56 is yoke insertion member 44, which is typically a notched or slotted wheel, having at least one, preferably at least two defined engagement slots 80, 82 for mating insertion of a male insertion member 68 affixed to one end of latch handle 42 when the handle is in the non-retracted position. Compressive counterclockwise movement of latch handle 42 about latch pivot pin 40 into side frame recess 70 releases the male insertion member 68 from one of mating slots 80 or 82 and permits free rotational movement of seat member 12, or back member 14 depending on the reference location, about main pivot pin 38. Releasing clockwise movement of latch handle 42 re-engages male insertion member 68 into mating slots 80 or 82. It is understood that in the embodiment where only one slot is within insertion member 44, that slot 80 is the essential slot. While a slotted arrangement has been described, it is envisioned that a serrated gear and pawl arrangement is within the scope of this invention.

In order to further minimize space requirements of car seat 10, as illustrated in FIG. 5, the curvilinear shape of front top side 22 is essentially duplicated by the curvilinear shape of top side 60 of seat back 14.

FIG. 9 illustrates another embodiment of this invention wherein a top-mounted latch release is illustrated in contrast to the rear-mounted latch release shown in FIGS. 1 - 6. In this embodiment, a pair of elongated handles 76 are positioned within the hollow wells of back seat sides 16, each of said handles in connected engagement with each other via connecting top segment 94. Each of the handles is downwardly biased by spring 74 in contact with internal ledge 72. Upward longitudinal axial compression effected by upward movement of top segment 94, handle tip 78 is retracted from its fully extended engagement position so as to permit pivotal counterclockwise rotational movement of back member 14 toward seat member 12 with subsequent reinsertion of handle tip 78 into mating recess 82. While elongated handles 76 are shown in the figure, it is equally applicable that these handles could be replaced by cables which would extend from the release handle 94 down each side of the back to two small spring biased plungers that engage the slots on the seat. The plungers are released by pulling the handle in an upward direction.

FIG. 10 illustrates yet another embodiment of this invention wherein a top-mounted latch release is illustrated which utilizes a rocker arm arrangement. In this embodiment, upward longitudinal axial movement of elongated handle 76 effects counterclockwise rotational movement about pivot pin 40 by physical contact with a slightly beveled projection 86 on rocker arm 84, thereby retracting a second projection 88 and permitting counterclockwise rotational movement of back member 14 toward seat member 12 with subsequent reinsertion of second projection 88 into mating recess 82 through the biasing force effected by spring 90 coupled downward longitudinal axial movement of elongated handle member 76 by release of top segment 94. As described with reference to FIG. 9, it is equally applicable that the handle member could be replaced by cables and the dual notch arrangement could be replaced by a single notch arrangement described previously. In yet another embodiment, the rocker arm is pivotally connected to handle 76 via pivot pin 152 illustrated in FIG. 10a.

FIGS. 7 - 8 illustrate still yet another embodiment of this invention wherein a bottom-mounted latch release is illustrated which once again utilizes a rocker arm arrangement. In this embodiment, upward movement of a first end 96 of rocker arm 104 effects downward movement of projection 108 on a second end of the rocker arm, thereby disengaging from contact with mating slot 112 in slotted yoke insertion wheel 100, thereby permitting counterclockwise rotational movement of back member 14 toward seat member 12 with subsequent reinsertion of projection 108 into mating recess 110 by the biasing force effected by spring 102 on rocker arm 104. It is noted that in this embodiment, the yoke arms 96 and yoke insertion member 100 are essentially the opposite from that described for the embodiment shown in FIGS. 1 - 6, thereby illustrating the interchangeability of this arrangement. It is once again recognized that the two notch arrangement may be interchangeably replaced with the one notch arrangement discussed previously. It is also easily recognized that the yoke arrangement is also interchangeable with the non-yoke arrangement illustrated in FIG. 7a, and that this arrangement is applicable to all of the embodiments shown in FIGS. 1-16.

FIGS. 11 - 13 illustrate one embodiment of a push-button release latch 112. Concentric to the pivot axis of the main pivot hinge 120, each pivot hinge or rivet having a head 126 and a retaining flange 124, is a relatively large button 112 which protrudes outwardly from either exterior side 62 of seat back sides 16. Each button is generally circular with at least one, preferably a pair of laterally-extending wings 132 to retain the button within the housing, each button being outwardly biased due to spring 114 within the housing. To release the seat member 12 from back member 14, each button must be depressed against the spring bias, thereby releasing the interlocking details which consist of at least one, preferably a pair of protrusions 134 in mating receptacles 128. When sufficient rotational movement has been achieved that seat member 12 is adjacent back member 14, the depressive force is removed and the seat and back members are retained in their collapsed position due to the interfacing of the newly positioned protrusions 134 in mating receptacle 130. It is recognized that in this arrangement, it is minimally required that the at lest one laterally extending wing 132 be capable of mating with at least one mating receptacle 128, and that the incorporation of additional wings and mating receptacles are optional.

FIGS. 14 - 16 illustrate yet another embodiment of a push-button release latch 140 retained in place by wings 144. In this configuration, push-button 140 is illustrated to be capable of insertion into either open position hole 136 or collapsed position hole 138 by rotation about main pivot 38. Depression of button 140 which is outwardly biased by spring 142, permits counterclockwise rotational movement of back member 14 toward seat member 12. While two openings, 136 and 138 are illustrated, it is recognized that it is only critical that there be an open position hole 136, although it is preferred that the collapsed position hole 138 be present.

In manufacture, the car seat 10 is typically made of plastic, preferably polyolefin, more preferably rubber modified polypropylene and covered with a fabric, typically including a foamed backing material for the occupant. A non-exhaustive list of possible plastics would include polyolefins, polycarbonates, polyesters, polyurethanes, polyalkylene terephthalates, polysulfones, polyimides, polyphenylene ethers, styrenic polymers, polycarbonates, acrylic polymers, polyamides, polyacetals, halide containing polymers and polyolefin homopolymers and copolymers. Additionally included would be mixtures of different polymers, such as polyphenylene ether/styrenic resin blends, polyvinylchloride/ABS or other impact modified polymers, such as methacrylonitrile containing ABS, and polyester/ABS or polyester plus some other impact modifier may also be used. Such polymers are available commercially or may be made by means well known in the art.

More specifically, polymers of monoolefins and diolefins, for example would include polypropylene, polyisobutylene, polybutene-1, polymethylpentene-1, polyisoprene or polybutadiene, as well as polymers of cycloolefins, for instance of cyclopentene or norbornene, polyethylene (which optionally can be crosslinked), for example high density polyethylene (HDPE), low density polyethylene (LDPE) and linear low density polyethylene (LLDPE) may be used. Mixtures of these polymers, for example mixtures of polypropylene with polyisobutylene, polypropylene with polyethylene (for example PP/HDPE), may also be used. Also useful are copolymers of monoolefins and diolefins with each other or with other vinyl monomers, such as, for example, ethylene/propylene, LLDPE and its mixtures with LDPE, propylene/butene-1, ethylene/hexene, ethylene/ethylpentene, ethylene/heptene, ethylene/octene, propylene/butadiene, isobutylene/isoprene, ethylene/alkyl acrylates, ethylene/alkyl methacrylates, ethylene/vinyl acetate (EVA) or ethylene/acrylic acid copolymers (EAA) and their salts (ionomers) and terpolymers of ethylene with propylene and a diene, such as hexadiene, dicyclopentadiene or ethylidene-norbornene; as well as mixtures of such copolymers and their mixtures with polymers mentioned above, for example polypropylene/ethylene-propylene copolymers, LDPE/EVA, LDPE/EAA, LLDPE/EVA and LLDPE/EAA.

Thermoplastic polymers may also include styrenic polymers, such as polystyrene, poly-(p-methylstyrene), poly-(&agr;-methylstyrene), copolymers of styrene or .alpha.-methylstyrene with dienes or acrylic derivatives, such as, for example, styrene/butadiene, styrene/acrylonitrile, styrene/alkyl methacrylate, styrene/maleic anhydride, styrene/butadiene/ethyl acrylate, styrene/acrylonitrile/methacrylate; mixtures of high impact strength from styrene copolymers and another polymer, such as, for example, from a polyacrylate, a diene polymer or an ethylene/propylene/diene terpolymer; and block copolymers of styrene, such as, for example, styrene/butadiene/styrene, styrene/isoprene/styrene, styrene/ethylene/butylene/styrene or styrene/ethylene/propylene/styrene. Styrenic polymers may additionally or alternatively include graft copolymers of styrene or &agr;-methylstyrene such as, for example, styrene on polybutadiene, styrene on polybutadiene-styrene or polybutadiene-acrylonitrile; styrene and acrylonitrile (or methacrylonitrile) on polybutadiene; styrene and maleic anhydride or maleimide on polybutadiene; styrene, acrylonitrile and maleic anhydride or maleimide on polybutadiene; styrene, acrylonitrile and methyl methacrylate on polybutadiene, styrene and alkyl acrylates or methacrylates on polybutadiene, styrene and acrylonitrile on ethylene/propylene/diene terpolymers, styrene and acrylonitrile on polyacrylates or polymethacrylates, styrene and acrylonitrile on acrylate/butadiene copolymers, as well as mixtures of with the styrenic copolymers indicated above.

Nitrile polymers are also useful in the polymer composition of the invention. These include homopolymers and copolymers of acrylonitrile and its analogs such as methacrylonitrile, such as polyacrylonitrile, acrylonitrile/butadiene polymers, acrylonitrile/alkyl acrylate polymers, acrylonitrile/alkyl methacrylate/butadiene polymers, acrylonitrile/butadiene/styrene (ABS), and ABS which includes methacrylonitrile.

Polymers based on acrylic acids, include acrylic acid, methacrylic acid, methyl methacrylate acid and ethacrylic acid and esters thereof may also be used. Such polymers include polymethylmethacrylate, and ABS-type graft copolymers wherein all or part of the acrylonitrile-type monomer has been replaced by an acrylic acid ester or an acrylic acid amide. Polymers including other acrylic-type monomers, such as acrolein, methacrolein, acrylamide and methacrylamide may also be used.

Halogen-containing polymers may also be useful. These include resins such as polychloroprene, epichlorohydrin homopolymers and copolymers, polyvinyl chloride, polyvinyl bromide, polyvinyl fluoride, polyvinylidene chloride, chlorinated polyethylene, chlorinated polypropylene, fluorinated polyvinylidene, brominated polyethylene, chlorinated rubber, vinyl chloride-vinylacetate copolymer, vinyl chloride-ethylene copolymer, vinyl chloride-propylene copolymer, vinyl chloride-styrene copolymer, vinyl chloride-isobutylene copolymer, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-styrene-maleic anhydride tercopolymer, vinyl chloride-styrene-acrylonitrile copolymer, vinyl chloride-isoprene copolymer, vinyl chloride-chlorinated propylene copolymer, vinyl chloride-vinylidene chloride-vinyl acetate tercopolymer, vinyl chloride-acrylic acid ester copolymers, vinyl chloride-maleic acid ester copolymers, vinyl chloride-methacrylic acid ester copolymers, vinyl chloride-acrylonitrile copolymer and internally plasticized polyvinyl chloride.

Other useful thermoplastic polymers include homopolymers and copolymers of cyclic ethers, such as polyalkylene glycols, polyethylene oxide, polypropylene oxide or copolymers thereof with bis-glycidyl ethers; polyacetals, such as polyoxymethylene and those polyoxymethylene with contain ethylene oxide as a comonomer; polyacetals modified with thermoplastic polyurethanes, acrylates or methacrylonitrile containing ABS; polyphenylene oxides and sulfides, and mixtures of polyphenylene oxides with polystyrene or polyamides; polycarbonates and polyester-carbonates; polysulfones, polyethersulfones and polyetherketones; and polyesters which are derived from dicarboxylic acid and diols and/or from hydroxycarboxylic acids or the corresponding lactones, such as polyethylene terephthalate, polybutylene terephthalate, poly-1,4-dimethylioi-cyclohexane terephthalate, poly-[2,2,4-(4-hydroxyphenyl)-propane]terephthalate and polyhydroxybenzoates as well as block copolyetheresters derived from polyethers having hydroxyl end groups.

Polyamides and copolyamides which are derived from diamines and dicarboxylic acids and/or from aminocarboxylic acids or the corresponding lactams, such as polyamide-4, polyamide-6, polyamide-6/6, polyamide-6/10, polyamide-6/9, polyamide-6/12, polyamide-4/6, polyamide-11, polyamide-12, aromatic polyamides obtained by condensation of m-xylene, diamine and adipic acid; polyamides prepared from hexamethylene diamine and isophthalic and/or terephthalic acid and optionally an elastomer as modifier, for example, poly-2,4,4-trimethylhexamethylene terephthalamide or poly-m-phenylene isophthalamide may be useful. Further copolymers of the aforementioned polyamides with polyolefins, olefin copolymers, ionomers or chemically bonded or grafted elastomers; or with polyethers, such as for instance, with polyethylene glycol, polypropylene glycol or polytetramethylene glycols, and polyamides or copolyamides modified with EPDM or ABS may be used.

This invention has been described in detail with reference to specific embodiments thereof, including the respective best modes for carrying out each embodiment. It shall be understood that these illustrations are by way of example and not by way of limitation. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims.