Design template

Abstract

A design template includes a torso section being one of a group of a 95 th percentile male, 50 th percentile male and 5 th percentile female having each being one of a group of an ERECT posture, a NEUTRAL posture and a SLUMPED posture.

What is claimed:  
     
         1 . A design template comprising: 
 a torso section being one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female having each being one of a group comprising an ERECT posture, a NEUTRAL posture and a SLUMPED posture.    
     
     
         2 . A design template as set forth in  claim 1  wherein said torso section has a portion of an outer contour conforming to a deformed shape of an interface contour between a seat and a seated occupant.  
     
     
         3 . A design template as set forth in  claim 2  wherein said torso section includes anatomical details located relative to each other and the interface contour is located relative to said anatomical details.  
     
     
         4 . A design template as set forth in  claim 1  wherein said torso section is made of a sheet of a rigid material or represented in electronic media.  
     
     
         5 . A design template as set forth in  claim 1  wherein said torso section includes indicia of skeletal landmarks for a shoulder joint and a hip joint and an axis connected therebetween.  
     
     
         6 . A design template as set forth in  claim 1  wherein said torso section includes a centerline projection of a pelvis with indicia representing an ischial tuberosity, anterior superior iliac spine, pubic symphysis and sacrum.  
     
     
         7 . A design template as set forth in  claim 1  wherein said torso section includes indicia of spinal landmarks marked along a back portion thereof.  
     
     
         8 . A design template as set forth in  claim 1  wherein said torso section includes an angular scale for torso angle.  
     
     
         9 . A design template as set forth in  claim 1  wherein said torso section includes an angular scale for hip angle.  
     
     
         10 . A design template as set forth in  claim 1  wherein said torso section has an anterior shape that is anthropometrically and anatomically correct.  
     
     
         11 . A design template as set forth in  claim 1  wherein said torso section includes indicia for a shoulder joint, neck/shoulder junction and a sternum.  
     
     
         12 . A design template as set forth in  claim 1  including a thigh section connected to said torso section.  
     
     
         13 . A design template as set forth in  claim 12  wherein said thigh section is one of a group comprising a 95 th  percentile male, 50  th  percentile male and 5 th  percentile female.  
     
     
         14 . A design template as set forth in  claim 12  wherein said thigh section is made of a sheet of rigid material or represented in electronic media.  
     
     
         15 . A design template as set forth in  claim 12  including a hinge at a hip joint to connect said thigh section to said torso section.  
     
     
         16 . A design template as set forth in  claim 12  wherein said thigh section includes indicia of a hip joint and knee joint and an axis therebetween.  
     
     
         17 . A design template as set forth in  claim 12  wherein said torso section and said thigh section are geometrically congruent in a seated posture where they overlap on a seat cushion.  
     
     
         18 . A design template as set forth in  claim 12  wherein said thigh section has a deformed bottom contour representing a change from hard bone tissue to soft muscle tissue in contact with a seat cushion.  
     
     
         19 . A design template as set forth in  claim 12  wherein said thigh section includes indicia of a pointer for hip angle and an angular scale for knee angle.  
     
     
         20 . A design template as set forth in  claim 12  including a calf section connected to said thigh section.  
     
     
         21 . A design template as set forth in  claim 20  wherein said calf section is one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female.  
     
     
         22 . A design template as set forth in  claim 20  wherein said calf section is made of a sheet of rigid material or represented in electronic media.  
     
     
         23 . A design template as set forth in  claim 20  including a hinge at a knee joint to connect said calf section to said thigh section.  
     
     
         24 . A design template as set forth in  claim 20  wherein said calf section includes indicia of a knee joint and ankle joint and an axis therebetween.  
     
     
         25 . A design template as set forth in  claim 20  wherein said calf section includes indicia of a pointer for knee angle and a scale for ankle angle.  
     
     
         26 . A design template as set forth in  claim 20  wherein said calf section and said thigh section are geometrically congruent in a seated posture where they overlap on anterior and superior surfaces.  
     
     
         27 . A design template as set forth in  claim 20  including a shoe section connected to said calf section.  
     
     
         28 . A design template as set forth in  claim 27  wherein said shoe section is one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female.  
     
     
         29 . A design template as set forth in  claim 27  wherein said shoe section is made of a sheet of rigid material or represented in electronic media.  
     
     
         30 . A design template as set forth in  claim 27  including a hinge at an ankle joint to connect said shoe section to said calf section.  
     
     
         31 . A design template as set forth in  claim 27  wherein said shoe section includes indicia for an ankle joint and a pointer for an ankle angle.  
     
     
         32 . A design template as set forth in  claim 27  wherein said shoe section has an axis from a ball of foot to heel of foot inside a shoe.  
     
     
         33 . An occupant restraint system for a seat comprising: 
 a lap belt being anchored to vehicle structure to extend below an anterior superior iliac spine and above an anterior inferior iliac spine for a design template with a torso section having an ERECT posture; and    a shoulder belt being anchored to vehicle structure to extend between a first predetermined distance from a centerline of the seat to a shoulder joint for a design template with a torso section being one of a group comprising a 5 th  percentile female, a 95 th  percentile male and a 50 th  percentile male and a second predetermined distance from the centerline of the seat to a neck/shoulder junction for the design template with the torso section being one of the group of the 5 th  percentile female, 50 th  percentile male or the 95 th  percentile male.    
     
     
         34 . An occupant restraint system as set forth in  claim 33  wherein said first predetermined distance is 190 mm for the 5 th  percentile female, 246 mm for the 50 th  percentile male and 267 mm for the 95 th  percentile male, and said second predetermined distance is 51 mm for the 5 th  percentile female, 65 mm for the 50 th  percentile male and 71 mm for the 95 th  percentile male.  
     
     
         35 . A method of establishing occupant accommodation criteria in a vehicle package based on a predetermined class of vehicles comprising: 
 providing a design template having a torso section being one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5  th  percentile female having each being one of a group comprising an ERECT posture, a NEUTRAL posture and a SLUMPED posture and having a leg section;    defining an accelerator to provide a heel point of the leg section;    defining deflection of a seat whether it is high deflection (soft), medium deflection (medium) or low deflection (hard);    positioning the design template in the vehicle such that the heel of the leg section is at the heel point and angles of the leg section are within predetermined comfort ranges;    establishing a seat height from a floor to a bottom of the torso section at I D   o ; and    establishing an H-point reference point (HptRP) relative to the heel point in a vehicle axis system by the design template.    
     
     
         36 . A method as set forth in  claim 35  including the step of adjusting joint angles at an ankle, knee and hip of the design template to lie within a predetermined range.  
     
     
         37 . A method as set forth in  claim 35  including the step of reclining the torso section a predetermined angle from vertical.  
     
     
         38 . A method as set forth in  claim 35  including locating an eye relative to a shoulder joint.  
     
     
         39 . A method as set forth in  claim 35  including the step of marking a location of a heel point and H-point.  
     
     
         40 . A method as set forth in  claim 35  including the step of positioning a heel on a depressed floorboard with a foot axis parallel to an undepressed accelerator pedal axis.  
     
     
         41 . A method as set forth in  claim 35  including the step of locating a center of the hip joint to define the H-point.  
     
     
         42 . A method as set forth in  claim 35  including the step of positioning a heel of the 5 th  percentile female having one of the ERECT posture, NEUTRAL posture or SLUMPED posture in the vehicle package.  
     
     
         43 . A method as set forth in  claim 35  including the step of positioning a heel of the 50 th  percentile male having one of the ERECT posture, NEUTRAL posture or SLUMPED posture in the vehicle package.  
     
     
         44 . A method as set forth in  claim 35  including the step of constructing a line parallel to a travel axis of a seat track in the vehicle package.  
     
     
         45 . A method as set forth in  claim 35  including the step of defining the H-point reference point at the rearmost and downmost position of the seat in the vehicle package.  
     
     
         46 . A method for designing a seat comprising: 
 selecting at least one design template having a torso section being one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female having each being one of a group comprising an ERECT posture, a NEUTRAL posture and a SLUMPED posture and having a leg section; and    forming load supporting contours of the seat for the at least one design template; and    forming unloaded contours of the seat for the at least one design template.    
     
     
         47 . A method as set forth in  claim 46  including the step of tracing an interface contour of the design template.  
     
     
         48 . A method as set forth in  claim 46  including the step of estimating a first point of the load supporting contours of a seat back at S o  under occupant load.  
     
     
         49 . A method as set forth in  claim 48  including the step of estimating a second point at S U  on the unloaded contour of the seat back.  
     
     
         50 . A method as set forth in  claim 46  including the step of estimating a first point of the load supporting contours of a seat back at L o  under occupant load.  
     
     
         51 . A method as set forth in  claim 50  including the step of estimating a second point at L U  on the unloaded contour of the seat back.  
     
     
         52 . A method as set forth in  claim 46  including the step of estimating a first point of the load supporting contours of a seat cushion at I D   o  under occupant load.  
     
     
         53 . A method as set forth in  claim 52  including the step of estimating a second point at I D   U  on the unloaded contour of the seat cushion.  
     
     
         54 . A method as set forth in  claim 46  including the step of estimating a first point of the load supporting contours of a seat cushion at T o  under occupant load.  
     
     
         55 . A method as set forth in  claim 54  including the step of estimating a second point at T U  on the unloaded contour of the seat cushion.  
     
     
         56 . A method as set forth in claims  49 ,  51 ,  53 ,  55  including the step of plotting locations of S U , L U , I D   U , and T U  points to form the unloaded contour of the seat for the design template.  
     
     
         57 . A method as set forth in  claim 56  including the step of optimally matching the unoccupied load support points for the other torso sections and postures of the design template to define the unoccupied contour.  
     
     
         58 . A method as set forth in  claim 57  including the step of constructing an unloaded point S U  for each of the design templates.  
     
     
         59 . A method as set forth in  claim 57  including the step of constructing an unloaded point L U  for each of the design templates.  
     
     
         60 . A method as set forth in  claim 57  including the step of constructing an unloaded point I D   U  for each of the design templates.  
     
     
         61 . A method as set forth in  claim 57  including the step of constructing an unloaded point T U  for each of the design templates.  
     
     
         62 . A method as set forth in  claim 46  including the step of defining the unoccupied load support zone for the thorax.  
     
     
         63 . A method as set forth in  claim 46  including the step of defining the unoccupied seat contour for the lumbar.  
     
     
         64 . A method as set forth in  claim 46  including the step of defining the unoccupied seat contour for the ischium.  
     
     
         65 . A method as set forth in  claim 46  including the step of defining an area for a seat suspension in the seat.  
     
     
         66 . A method as set forth in  claim 46  including the step of defining an unoccupied seat contour for the thigh.  
     
     
         67 . A method as set forth in  claim 46  including the step of defining a waterfall region of an unoccupied seat.  
     
     
         68 . A method of using a design template to design a vehicle seat comprising: 
 providing at least one design template having a torso section being one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female having each being one of a group comprising an ERECT posture, a NEUTRAL posture and a SLUMPED posture;    establishing occupant accommodation criteria based on positioning the at least one design template in a predetermined class of vehicles to define seat height and seat track displacement to accommodate each design template on a seat having a seat cushion and a seat back in a vehicle representing the vehicle package criteria; and    defining at least one from a group comprising unloaded contours on the seat at S U , L U , I D   U  and T U ;    defining at least one from a group comprising a seat back height, seat cushion length, head restraint position, thorax support, lumbar support, seat back bite line region, seat cushion bite line region, seat cushion bolster and seat suspension for the seat relative to the design template.    
     
     
         69 . A method as set forth in  claim 68  wherein said step of defining a seat back height for the seat relative to the design template comprises terminating a seat back height relative to the design template at T 2  on the torso section of the 50 th  percentile male having the ERECT posture.  
     
     
         70 . A method as set forth in  claim 68  wherein said step of defining a seat back height for the seat relative to the design template comprises locating a top cross member of the seat back frame relative to the design template at a position equal to or higher than T 4  on the torso section of the 50 th  percentile male having the ERECT posture.  
     
     
         71 . A method as set forth in  claim 68  wherein said step of defining a head restraint position for the seat relative to the design template comprises calculating a position of an eye relative to the design template, locating a back of a head for the torso section of the 95 th  percentile male having the ERECT posture relative to the calculated position of the eye, and defining a lowest maximum height of the head restraint relative to the design template at the back of the head for the torso section of the 95 th  percentile male having the ERECT posture.  
     
     
         72 . A method as set forth in  claim 68  wherein said step of defining a thorax support for the seat relative to the design template comprises defining an area for the thorax support relative to the design template between a thorax load zone for the torso section of the 95 th  percentile male having the ERECT posture and the thorax load zone for the torso section of the 5 th  percentile female having the SLUMPED posture.  
     
     
         73 . A method as set forth in  claim 68  wherein said step of defining a lumbar support for the seat relative to the design template comprises locating a two-way, horizontal displacement, adjustable lumbar support for the seat relative to the design template between L 3  and L 4  for the torso section of the 95 th  percentile male having the ERECT posture.  
     
     
         74 . A method as set forth in  claim 68  wherein said step of defining a lumbar support for the seat relative to the design template comprises locating vertical displacement of an adjustable lumbar support for the seat relative to the design template between L 2  and L 5  for the torso section of the 95 th  percentile male having the ERECT posture.  
     
     
         75 . A method as set forth in  claim 68  wherein said step of defining a lumbar support for the seat relative to the design template comprises defining structural mechanics of a deformable pad of the seat back relative to the design template so that the pad bends easily at T 12  for the torso section of the 95 th  percentile male having the ERECT posture and at S 1  for the torso section of the 95 th  percentile male having the ERECT posture.  
     
     
         76 . A method as set forth in  claim 68  wherein said step of defining a seat back bite line region for the seat relative to the design template comprises locating structure in the seat back to restrain rearward motion of the occupant into the seat back relative to the design template within a region bounded by S 1  for the torso section of the 95 th  percentile male having the ERECT posture and S 1  for the torso section of the 5th percentile female having the NEUTRAL posture.  
     
     
         77 . A method as set forth in  claim 68  wherein said step of defining a seat back bite line region for the seat relative to the design template comprises locating non-deformable structures in the seat back relative to the design template equal to or above S 1  for the torso section of the 5 th  percentile female having the NEUTRAL posture.  
     
     
         78 . A method as set forth in  claim 68  wherein said step of defining a seat cushion bite line region for the seat relative to the design template comprises locating non-deformable structures relative to the design template below a horizontal tangent at an I D   o  load supporting contour for the torso section of the 95 th  percentile male having the ERECT posture.  
     
     
         79 . A method as set forth in  claim 68  wherein said step of defining a seat suspension for the seat relative to the design template comprises defining an area for the seat suspension relative to the design template between a furthest forward and rearward ischial load points for the torso section of the 95 th  percentile male having the SLUMPED posture and for the torso section of the 5 th  percentile female having the ERECT posture.  
     
     
         80 . A method as set forth in  claim 68  wherein said step of defining a seat cushion length for the seat relative to the design template comprises terminating a length of the seat cushion relative to the design template from I D  on the torso section of the 5 th  percentile female having the ERECT posture to a vertical line passing through a knee point and a thigh axis on the torso section of the 5 th  percentile female having the NEUTRAL posture.  
     
     
         81 . A seat comprising: 
 a seat cushion;    a seat back associated with said seat cushion; and    at least one from a group comprising a seat back height, seat cushion length, head restraint position, thorax support, lumbar support, seat back bite line region, seat cushion bite line region and seat suspension being defined for said seat cushion and said seat back relative to a design template having a torso section being one of a group comprising a 95 th  percentile male, 50 th  percentile male and 5 th  percentile female having each being one of a group comprising an ERECT posture, a NEUTRAL posture and a SLUMPED posture and having a leg section.    
     
     
         82 . A seat as set forth in  claim 81  wherein said seat back height of said seat back terminates at T 2  on the torso section of the 50 th  percentile male having the ERECT posture for the design template.  
     
     
         83 . A seat as set forth in  claim 81  wherein said seat back includes a top cross member at a position equal to or higher than T 4  on the torso section of the 50 th  percentile male having the ERECT posture for the design template.  
     
     
         84 . A seat as set forth in  claim 81  wherein said head restraint position is located relative to a position of a back of a head for the torso section of the 95 th  percentile male having the ERECT posture for the design template.  
     
     
         85 . A seat as set forth in  claim 81  wherein said seat cushion bite line region includes non-deformable structures located below a horizontal tangent at an I D  load supporting contour and non-deformable structures located rearward of a tangent to the S o  and L o  points for the torso section of the 95 th  percentile male having the ERECT posture for the design template.  
     
     
         86 . A seat as set forth in  claim 81  wherein said seat back bite line region includes structure in said seat back to restrain rearward motion of an occupant into said seat back located within a region bounded by S 1  for the torso section of the 95 th  percentile male having the ERECT posture and S 1  for the torso section of the 5 th  percentile female having the NEUTRAL posture for the design template.  
     
     
         87 . A seat as set forth in  claim 81  wherein said seat back bite line region includes non-deformable structures in said seat back located equal to or above S 1  for the torso section of the 5 th  percentile female having the NEUTRAL posture for the design template.  
     
     
         88 . A seat as set forth in  claim 81  wherein said two-way, horizontal displacement, lumbar support is located between L 3  and L 4  for the torso section of the 95 th  percentile male having the ERECT posture for the design template.  
     
     
         89 . A seat as set forth in  claim 81  wherein said lumbar support is located for vertical displacement between L 2  and L 5  on the torso section of the 95 th  percentile male having the ERECT posture for the design template.  
     
     
         90 . A seat as set forth in  claim 81  wherein said lumbar support includes a deformable pad that bends easily at T 12  and S 1  for the torso section of the 95th percentile male having the ERECT posture for the design template.  
     
     
         91 . A seat as set forth in  claim 81  wherein said seat cushion length terminates from I D  on the torso section of the 5 th  percentile female having the ERECT posture to a vertical line passing through a knee point with a thigh axis parallel to an axis passing through I D  and T load supporting contours on the torso section of the 5 th  percentile female having the NEUTRAL posture for the design template.  
     
     
         92 . A seat as set forth in  claim 81  wherein said seat suspension is defined in an area between a furthest forward and rearward ischial load zone for the torso section of the I D  load supporting contour for the design template.  
     
     
         93 . A seat as set forth in  claim 81  including a seat anti-submarining restraint system defined in an area between a furthest forward ischial load zone for the torso section of the I D  load supporting contour for the design template and the vertical barrier at the nose of the seat cushion to horizontal motion of the ischium for the design template.  
     
     
         94 . A seat as set forth in  claim 81  wherein said thorax support is defined in an area between a thorax load zone for the torso section of the 95 th  percentile male having the ERECT posture and a thorax load zone for the torso section of the 5 th  percentile female having the SLUMPED posture for the design template.  
     
     
         95 . A seat as set forth in  claim 81  including a structural cross-member of the seat back anchored to the seat back frame at the level of the S 1  for the design template with the torso section being one of the 5 th  percentile female having an ERECT posture and the 95th percentile male having a NEUTRAL posture.  
     
     
         96 . A seat as set forth in  claim 81  including an anti-submarining region in the most forward portion of the seat cushion having a vertical barrier to horizontal motion of the ischium in a design template being the 5 th  percentile female having one of the group of ERECT, NEUTRAL or SLUMPED postures.